SEBU6883-08

July 2007

Operation and
Maintenance
Manual
G3408C and G3412C Engines
6ZM1-Up (Engine)
3WR1-Up (Engine)
9RR1-Up (Engine)
6FW1-Up (Engine)
8LW1-Up (Engine)
BAZ1-Up (Engine)
 i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SEBU6883-08 3
Table of Contents

Table of Contents Reference Materials .............................................. 98

Index Section
Foreword ................................................................. 4
Index ................................................................... 103
Safety Section
Safety Messages .................................................... 6

General Hazard Information ................................. 10

Burn Prevention .................................................... 12

Fire Prevention and Explosion Prevention ............ 13

Crushing Prevention and Cutting Prevention ........ 14

Mounting and Dismounting ................................... 15

Ignition Systems ................................................... 15

Before Starting Engine .......................................... 15

Engine Starting ..................................................... 16

Engine Stopping ................................................... 16

Electrical System .................................................. 16

Product Information Section

Model Views and Specifications ........................... 18

Product Identification Information ........................ 24

Operation Section
Lifting and Storage ................................................ 26

Gauges and Indicators .......................................... 28

Features and Controls .......................................... 31

Engine Starting ..................................................... 42

Engine Operation .................................................. 47

Engine Stopping ................................................... 48

Maintenance Section
Refill Capacities .................................................... 50

Maintenance Interval Schedule (Standard) .......... 54

Maintenance Interval Schedule (Standby) ............ 56

Reference Information Section

Customer Service ................................................. 96
4 SEBU6883-08
Foreword
Foreword
Literature Information
This manual contains safety, operation instructions,
lubrication and maintenance information. This
manual should be stored in or near the engine area
in a literature holder or literature storage area. Read,
study and keep it with the literature and engine
information.
English is the primary language for all Caterpillar
publications. The English used facilitates translation
and consistency in electronic media delivery.
Some photographs or illustrations in this manual
show details or attachments that may be different
from your engine. Guards and covers may have
been removed for illustrative purposes. Continuing
improvement and advancement of product design
may have caused changes to your engine which are
not included in this manual. Whenever a question
arises regarding your engine, or this manual, please
consult with your Caterpillar dealer for the latest
available information.
Safety
This safety section lists basic safety precautions.
In addition, this section identifies hazardous,
warning situations. Read and understand the basic
precautions listed in the safety section before
operating or performing lubrication, maintenance and
repair on this product.
Operation
Operating techniques outlined in this manual are
basic. They assist with developing the skills and
techniques required to operate the engine more
efficiently and economically. Skill and techniques
develop as the operator gains knowledge of the
engine and its capabilities.
The operation section is a reference for operators.
Photographs and illustrations guide the operator
through procedures of inspecting, starting, operating
and stopping the engine. This section also includes a
discussion of electronic diagnostic information.
Maintenance
The maintenance section is a guide to engine care.
The illustrated, step-by-step instructions are grouped
by service hours and/or calendar time maintenance
intervals. Items in the maintenance schedule are
referenced to detailed instructions that follow.
Use service hours to determine intervals. Calendar
intervals shown (daily, annually, etc) may be used
instead of service meter intervals if they provide more
convenient schedules and approximate the indicated
service meter reading.
Recommended service should always be
performed at the service hour interval. The actual
operating environment of the engine also governs
the maintenance schedule. Therefore, under
extremely severe, dusty, wet or freezing cold
operating conditions, more frequent lubrication and
maintenance than is specified in the maintenance
schedule may be necessary.
The maintenance schedule items are organized for
a preventive maintenance management program. If
the preventive maintenance program is followed, a
periodic tune-up is not required. The implementation
of a preventive maintenance management program
should minimize operating costs through cost
avoidances resulting from reductions in unscheduled
downtime and failures.
Maintenance Intervals
Perform maintenance on items at multiples of the
original requirement. Each level and/or individual
items in each level should be shifted ahead or back
depending upon your specific maintenance practices,
operation and application. We recommend that
the maintenance schedules be reproduced and
displayed near the engine as a convenient reminder.
We also recommend that a maintenance record be
maintained as part of the engine’s permanent record.
See the section in the Operation and Maintenance
Manual, “Maintenance Records” for information
regarding documents that are generally accepted
as proof of maintenance or repair. Your authorized
Caterpillar dealer can assist you in adjusting your
maintenance schedule to meet the needs of your
operating environment.
California Proposition 65 Warning
Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands after
handling.
SEBU6883-08 5
Foreword

Overhaul
Major engine overhaul details are not covered in the
Operation and Maintenance Manual except for the
interval and the maintenance items in that interval.
Major repairs are best left to trained personnel or
an authorized Caterpillar dealer. Your Caterpillar
dealer offers a variety of options regarding overhaul
programs. If you experience a major engine failure,
there are also numerous after failure overhaul options
available from your Caterpillar dealer. Consult with
your dealer for information regarding these options.
6 SEBU6883-08
Safety Section
Safety Messages

Safety Section
i02803087

Safety Messages
SMCS Code: 1000; 7405

There may be several specific safety messages on

your engine. The exact location and a description of
the messages are reviewed in this section. Please
become familiar with all of the messages.

Ensure that all of the messages are legible. Clean

the messages or replace the messages if the
words cannot be read or if the illustrations are not
visible. Use a cloth, water, and soap for cleaning
the messages. Do not use solvents, gasoline, or
other harsh chemicals. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
messages. The messages that are loosened could
drop off of the engine.

Replace any message that is damaged or missing.

If a message is attached to a part of the engine
that is replaced, install a new message on the
replacement part. Your Caterpillar dealer can provide
new messages.

Do not operate or work on the engine unless the

instruction and warnings in the Operation and
Maintenance Manual are understood. Failure to
follow the instructions or failure to heed the warnings
could result in injury or death. Proper care is your
responsibility.

Note: Your engine will have “Type 1” safety

messages or “Type 2” safety messages.
SEBU6883-08 7
Safety Section
Safety Messages

Type 1

g01276147
Illustration 1

1 Universal Safety Message

The safety message for reading the manual before Do not operate or work on this engine or genera-
operating the unit is located on the outside of the tor set unless you have read and understand the
door of the control panel. instructions and warnings in the Operation and
Maintenance Manuals.

Failure to follow the warnings and instructions

could result in injury or death. Contact any
Caterpillar dealer for replacement manuals. Prop-
er care is your responsibility.

2 Entanglement
The safety message for entanglement (if equipped)
is located on the clutch housing.

g00306265
Illustration 2
8 SEBU6883-08
Safety Section
Safety Messages

g00107407
Illustration 3

Rotating gears can cause entanglement of fingers

or entanglement of hands. Do not service this
component without first reading the Operation and
Maintenance Manual.

Type 2

g01394248
Illustration 4
View of the right side of a typical G3408 or G3412 Engine
(1) Universal warning (2) Shock hazard
SEBU6883-08 9
Safety Section
Safety Messages

g01394247
Illustration 5
View of the left side of a typical G3408 or G3412 Engine
(1) Universal warning (2) Shock hazard (3) Hazardous environment (if equipped)

1 Universal Safety Message 2 Shock Hazard

The universal safety message is located on the base The safety message for shock hazards is located
of the front valve cover on each side of the engine. on the base of the back valve cover on each side
of the engine.

g01370904
Illustration 6
g01372247
Illustration 7

Do not operate or work on this machine unless

you have read and understand the instructions
and warnings in the Operation and Maintenance
Manual. Failure to follow the instructions or heed
the warnings could result in injury or death. Con-
tact any Caterpillar dealer for replacement manu-
als. Proper care is your responsibility.
WARNING! Shock/Electrocution Hazard! Read and
understand the instructions and warnings in the
Operation and Maintenance Manual. Failure to fol-
low the instructions or heed the warnings could
cause serious injury or death.
10
Safety Section
General Hazard Information
3 Hazardous Environment (CSA)
The safety message for hazardous environment is
located on the front crankcase cover on the left side
of the engine.
g01397609
Illustration 8
Do not disconnect equipment unless power has
been disconnected or the area is known to be non-
hazardous.
i02602865
General Hazard Information
SMCS Code: 1000; 4450; 7405
g00104545
Illustration 9
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls
before the engine is serviced or before the engine is
repaired. These warning tags (Special Instruction,
SEHS7332) are available from your Caterpillar
dealer. Attach the warning tags to the engine and to
each operator control station. When it is appropriate,
disconnect the starting controls.
SEBU6883-08
Do not allow unauthorized personnel on the engine,
or around the engine when the engine is being
serviced.
Engine exhaust contains products of combustion
which may be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is in an enclosed area, vent the
engine exhaust to the outside.
Cautiously remove the following parts. To help
prevent spraying or splashing of pressurized fluids,
hold a rag over the part that is being removed.
• Filler caps
• Grease fittings
• Pressure taps
• Breathers
• Drain plugs
Use caution when cover plates are removed.
Gradually loosen, but do not remove the last two
bolts or nuts that are located at opposite ends of
the cover plate or the device. Before removing the
last two bolts or nuts, pry the cover loose in order to
relieve any spring pressure or other pressure.
g00702020
Illustration 10
• Wear a hard hat, protective glasses, and other
protective equipment, as required.
• When work is performed around an engine that is
operating, wear protective devices for ears in order
to help prevent damage to hearing.
• Do not wear loose clothing or jewelry that can snag
on controls or on other parts of the engine.
• Ensure that all protective guards and all covers are
secured in place on the engine.
• Never put maintenance fluids into glass containers.
Glass containers can break.
SEBU6883-08 11
Safety Section
General Hazard Information

• Use all cleaning solutions with care.
• Report all necessary repairs.
Unless other instructions are provided, perform
the maintenance under the following conditions:
• The engine is stopped. Ensure that the engine
cannot be started.
• Disconnect the batteries when maintenance
is performed or when the electrical system is
serviced. Disconnect the battery ground leads.
Tape the leads in order to help prevent sparks.
• Do not attempt any repairs that are not understood.
Use the proper tools. Replace any equipment that
is damaged or repair the equipment.
California Proposition 65 Warning
Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
Containing Fluid Spillage
Care must be taken in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
engine. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component that contains fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tools Catalog” for the following items:

Some engine exhaust constituents are known to the • Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids
State of California to cause cancer, birth defects, and
other reproductive harm.
• Tools that are suitable for containing fluids and
equipment that is suitable for containing fluids
Pressurized Air and Water
Obey all local regulations for the disposal of liquids.
Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result in
personal injury.
Asbestos Information

When pressurized air and/or pressurized water is

used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.

The maximum air pressure for cleaning purposes

must be below 205 kPa (30 psi) when the air nozzle
is deadheaded. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi).

Fluid Penetration
g00702022
Illustration 12

Caterpillar equipment and replacement parts that are

shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines
when you handle any replacement parts that contain
asbestos or when you handle asbestos debris.

g00687600
Illustration 11
12
Safety Section
Burn Prevention
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Never use compressed air for cleaning.
• Avoid brushing materials that contain asbestos.
• Avoid grinding materials that contain asbestos.
• Use a wet method in order to clean up asbestos
materials.
• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
• Use exhaust ventilation on permanent machining
jobs.
• Wear an approved respirator if there is no other
way to control the dust.
• Comply with applicable rules and regulations
for the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
• Obey environmental regulations for the disposal
of asbestos.
• Stay away from areas that might have asbestos
particles in the air.
SEBU6883-08
Dispose of Waste Properly
g00706404
Illustration 13
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
i01480768
Burn Prevention
SMCS Code: 1000; 4450; 7405
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance
is performed on the engine. Relieve all pressure
in the air system, in the hydraulic system, in the
lubrication system, in the fuel system, or in the
cooling system before any lines, fittings or related
items are disconnected.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
Check the coolant level after the engine has stopped
and the engine has been allowed to cool.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
SEBU6883-08
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Oils
Hot oil and hot lubricating components can cause
personal injury. Do not allow hot oil to contact the
skin. Also, do not allow hot components to contact
the skin.
Batteries
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for servicing
batteries. Wash hands after touching the batteries
and connectors. Use of gloves is recommended.
i01372262
Fire Prevention and Explosion
Prevention
SMCS Code: 1000; 4450; 7405
g00704000
Illustration 14
All fuels, most lubricants, and some coolant mixtures
are flammable.
Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause
a fire. Fire may cause personal injury and property
damage.
A flash fire may result if the covers for the engine
crankcase are removed within fifteen minutes after
an emergency shutdown.
Determine whether the engine will be operated in an
environment that allows combustible gases to be
drawn into the air inlet system. These gases could
cause the engine to overspeed. Personal injury,
property damage, or engine damage could result.
13
Safety Section
Fire Prevention and Explosion Prevention
If the application involves the presence of combustible
gases, consult your Caterpillar dealer for additional
information about suitable protection devices.
Remove all flammable materials such as fuel, oil, and
debris from the engine. Do not allow any flammable
materials to accumulate on the engine.
Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
Do not expose the engine to any flame.
Exhaust shields (if equipped) protect hot exhaust
components from oil or fuel spray in case of a line,
a hose, or a seal failure. Exhaust shields must be
installed correctly.
Do not weld on lines or tanks that contain flammable
fluids. Do not flame cut lines that contain flammable
fluid. Clean any such lines thoroughly with a
nonflammable solvent prior to welding or flame
cutting.
Wiring must be kept in good condition. All electrical
wires must be properly routed and securely attached.
Check all electrical wires daily. Repair any wires
that are loose or frayed before you operate the
engine. Clean all electrical connections and tighten
all electrical connections.
Eliminate all wiring that is unattached or unnecessary.
Do not use any wires or cables that are smaller than
the recommended gauge. Do not bypass any fuses
and/or circuit breakers.
Arcing or sparking could cause a fire. Secure
connections, recommended wiring, and properly
maintained battery cables will help to prevent arcing
or sparking.
Inspect all lines and hoses for wear or for
deterioration. The hoses must be properly routed.
The lines and hoses must have adequate support
and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.
Oil filters and fuel filters must be properly installed.
The filter housings must be tightened to the proper
torque.
14
Safety Section
Crushing Prevention and Cutting Prevention
g00704135
Illustration 15
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
a hydrometer.
Improper jumper cable connections can cause
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. This may cause an
explosion.
The batteries must be kept clean. The covers
(if equipped) must be kept on the cells. Use the
recommended cables, connections, and battery box
covers when the engine is operated.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
Lines, Tubes and Hoses
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent
or damaged.
SEBU6883-08
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Caterpillar dealer for
repair or for replacement parts.
Check lines, tubes and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections
to the recommended torque.
Replace the parts if any of the following conditions
are present:
• End fittings are damaged or leaking.
• Outer coverings are chafed or cut.
• Wires are exposed.
• Outer coverings are ballooning.
• Flexible part of the hoses are kinked.
• Outer covers have embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During engine operation, this
will help to prevent vibration, rubbing against other
parts, and excessive heat.
i01359666
Crushing Prevention and
Cutting Prevention
SMCS Code: 1000; 4450; 7405
Support the component properly when work beneath
the component is performed.
Unless other maintenance instructions are provided,
never attempt adjustments while the engine is
running.
Stay clear of all rotating parts and of all moving
parts. Leave the guards in place until maintenance
is performed. After the maintenance is performed,
reinstall the guards.
Keep objects away from moving fan blades. The fan
blades will throw objects or cut objects.
When objects are struck, wear protective glasses in
order to avoid injury to the eyes.
Chips or other debris may fly off objects when objects
are struck. Before objects are struck, ensure that no
one will be injured by flying debris.
SEBU6883-08
i01372247
Mounting and Dismounting
SMCS Code: 1000; 4450; 7405
Inspect the steps, the handholds, and the work area
before mounting the engine. Keep these items clean
and keep these items in good repair.
Mount the engine and dismount the engine only at
locations that have steps and/or handholds. Do not
climb on the engine, and do not jump off the engine.
Face the engine in order to mount the engine or
dismount the engine. Maintain a three-point contact
with the steps and handholds. Use two feet and one
hand or use one foot and two hands. Do not use any
controls as handholds.
Do not stand on components which cannot support
your weight. Use an adequate ladder or use a work
platform. Secure the climbing equipment so that the
equipment will not move.
Do not carry tools or supplies when you mount the
engine or when you dismount the engine. Use a hand
line to raise and lower tools or supplies.
i01640342
Ignition Systems
SMCS Code: 1550
Ignition systems can cause electrical shocks. Avoid
contacting the ignition system components and
wiring.
Do not attempt to remove the valve covers when the
engine is operating. The transformers are grounded
to the valve covers. Personal injury or death may
result and the ignition system will be damaged if the
valve covers are removed during engine operation.
The engine will not operate without the valve covers.
When the ignition harness is reconnected, ensure
that the Engine Control Switch (ECS) is in the STOP
position or the OFF/RESET position so that the
ignition system is immediately discharged.
15
Safety Section
Mounting and Dismounting
If the wiring harness is reconnected with the ECS in
the AUTOMATIC position or the MANUAL START
position, the storage capacitor of the ignition system
may discharge. If the wiring harness is reconnected
with the ECS in the AUTOMATIC position or the
MANUAL START position, the storage capacitor of
the ignition system may fire a spark plug. The spark
plug will ignite any gas which is in the cylinder. The
crankshaft can rotate and the crankshaft can be
damaged. The driven equipment can also rotate and
the driven equipment can also be damaged. Personal
injury or damage to the equipment may be a result.
Gas that has accumulated in the exhaust system
may also be ignited.
i00659904
Before Starting Engine
SMCS Code: 1000
Inspect the engine for potential hazards.
Before starting the engine, ensure that no one is on,
underneath, or close to the engine. Ensure that the
area is free of personnel.
Ensure that the engine is equipped with a lighting
system that is suitable for the conditions. Ensure that
all lights work properly.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
Do not bypass the automatic shutoff circuits. Do not
disable the automatic shutoff circuits. The circuits are
provided in order to help prevent personal injury. The
circuits are also provided in order to help prevent
engine damage.
On the initial start-up of a new engine or an engine
that has been serviced, be prepared to stop the
engine if an overspeed condition occurs. This may
be accomplished by shutting off the fuel supply to the
engine, or shutting off the ignition system.
See the Service Manual for repairs and for
adjustments.
16
Safety Section
Engine Starting
i02136012
Engine Starting
SMCS Code: 1000
If a warning tag is attached to the engine start switch
or to the controls, DO NOT start the engine or move
the controls. Consult with the person that attached
the warning tag before the engine is started.
All protective guards and all protective covers must
be installed if the engine must be started in order
to perform service procedures. To help prevent an
accident that is caused by parts in rotation, work
around the parts carefully.
If there is a possibility that unburned gas remains in
the exhaust system, refer to the purge procedure in
this Operation and Maintenance Manual, “Engine
Starting” topic in the Operation Section.
Start the engine from the operator’s compartment or
from the engine start switch.
Always start the engine according to the procedure
that is described in the Operation and Maintenance
Manual, “Engine Starting” topic in the Operation
Section. Knowing the correct procedure will help to
prevent major damage to the engine components.
Knowing the procedure will also help to prevent
personal injury.
To ensure that the jacket water heater (if equipped)
and/or the lube oil heater (if equipped) is working
properly, check the water temperature and the oil
temperature during heater operation.
Engine exhaust contains products of combustion
which can be harmful to your health. Always start the
engine and operate the engine in a well ventilated
area. If the engine is started in an enclosed area,
vent the engine exhaust to the outside.
i00659907
Engine Stopping
SMCS Code: 1000
To avoid overheating of the engine and accelerated
wear of the engine components, stop the engine
according to the instructions in this Operation and
Maintenance Manual, “Engine Stopping” topic
(Operation Section).
SEBU6883-08
Use the Emergency Stop Button (if equipped) ONLY
in an emergency situation. Do not use the Emergency
Stop Button for normal engine stopping. After an
emergency stop, DO NOT start the engine until the
problem that caused the emergency stop has been
corrected.
On the initial start-up of a new engine or an engine
that has been serviced, make provisions to stop
the engine if an overspeed occurs. This may be
accomplished by shutting off the fuel supply to the
engine, or shutting off the ignition system.
i00887114
Electrical System
SMCS Code: 1000; 1400
Never disconnect any charging unit circuit or battery
circuit cable from the battery when the charging unit
is operating. A spark can cause the combustible
gases that are produced by some batteries to ignite.
Check the electrical wires daily for wires that are
loose or frayed. Tighten all loose electrical wires
before the engine is operated. Repair all frayed
electrical wires before the engine is started.
Grounding Practices
Proper grounding is necessary for optimum engine
performance and reliability. Improper grounding will
result in uncontrolled electrical circuit paths and in
unreliable electrical circuit paths.
Uncontrolled electrical circuit paths can result in
damage to main bearings, to crankshaft journal
surfaces, and to aluminum components. Uncontrolled
electrical circuit paths can also cause electrical
activity that may degrade the engine electronics and
communications.
For the starting motor, do not attach the battery
negative terminal to the engine block.
Use a ground strap to ground the case of all control
panels to the engine block.
Ground the engine block with a ground strap that is
furnished by the customer. Connect this ground strap
to the ground plane.
Use a separate ground strap to ground the battery
negative terminal for the control system to the ground
plane.
SEBU6883-08 17
Safety Section
Electrical System

Rubber couplings may connect the steel piping of

the cooling system and the radiator. This causes the
piping and the radiator to be electrically isolated.
Ensure that the piping and the radiator is continuously
grounded to the engine. Use ground straps that
bypass the rubber couplings.

Ensure that all grounds are secure and free of

corrosion.
18 SEBU6883-08
Product Information Section
Model Views and Specifications

Product Information
Section

Model Views and

Specifications
i02789044

Model View Illustrations

SMCS Code: 1000; 4450
S/N: 6ZM1-Up
S/N: BAZ1-Up

The illustrations show various typical features of

G3400C Engines. The illustrations do not show all of
the options that are available.

Your engine may look like the following engine.

g01393311
Illustration 16
View of the left side of a G3412 Engine
(1) Electronic ignition system module (5) Engine air cleaner (9) Gas pressure regulator
(2) Engine crankcase breather (6) Lifting eye (10) Drain valve for engine oil
(3) Aftercooler (7) Filler tube for oil (11) Drain for engine oil
(4) Control group (throttle) (8) Control panel for stopping
SEBU6883-08 19
Product Information Section
Model Views and Specifications

g01393312
Illustration 17
View of the right side of a G3412 Engine
(12) Sensor for nitrous oxide (15) Oil filters (18) Exhaust outlet
(13) Buffer for the sensor for nitrous oxide (16) Oil level gauge
(14) Oil sampling valve (17) Turbocharger

i02789109

Model View Illustrations

SMCS Code: 1000; 4450

The illustrations show various typical features of

G3400C Engines. The illustrations do not show all of
the options that are available.

Your engine may look like the following engine.

20 SEBU6883-08
Product Information Section
Model Views and Specifications

g01393356
Illustration 18
Typical engine
(1) Crankcase breather (5) Oil level gauge (9) Oil sampling valve
(2) Oil filler (6) Starting motor (10) Inlet for the water pump
(3) Electronic ignition system module (7) Oil filters (11) Vibration damper
(4) Lifting eyes (8) Oil drain
SEBU6883-08 21
Product Information Section
Model Views and Specifications

g01275731
Illustration 19
Typical engine
(12) Manual governor control lever (16) Exhaust (20) Emergency stop button
(13) Air cleaner (17) Gas pressure regulator (21) Flywheel housing
(14) Air filter service indicator (18) Gas shutoff valve (22) Auxiliary water pump
(15) Turbocharger (19) Junction box

i02798920 Fuel System

Product Description
SMCS Code: 1000; 4450
Note: The information in this manual refers to gas
engines with low pressure fuel systems.
The G3400 Series C Engines are standard engines
with low pressure gas fuel systems. These engines
are used for industrial applications and generator set
applications. The engines will successfully operate
on commercial pipeline natural gas and wellhead gas
(field gas).
For the low pressure gas fuel system, the carburetor
is located after the air cleaner. Filtered air and gas are
mixed in the carburetor. The mixture is compressed
by the turbocharger (if equipped). The fuel system
operates with a gas pressure between 10 to 34.5 kPa
(1.5 to 5 psi). The fluctuation of the fuel supply
pressure should not exceed ± 1.7 kPa (± 0.25 psi)
in order to maintain stable operation. This pressure
meets the “ISO8528 Class 1” standards for transient
response.
Ignition System
The engine is equipped with an Electronic Ignition
System (EIS) and conventional spark plugs.
The system provides dependable firing and low
maintenance. The system provides precise control of
the duration of the spark and the ignition timing.

The system also provides diagnostic capability that

enhances troubleshooting. Primarily, the ignition
wiring is routed externally. A short stretch of wire is
routed under the valve covers.
22 SEBU6883-08
Product Information Section
Model Views and Specifications

The engines are equipped with protection from i02748216

detonation. A detonation sensor is located on each
side of the cylinder block. The ignition timing is Specifications
retardedfor all cylinders when excessive detonation
is sensedfor any cylinder. If the maximum retarded SMCS Code: 1000
position is attained and detonation continues to
Table 1
occur, the ECM shuts down the engine.
G3400C Engine Specifications
Lubrication System Item G3408C Engine G3412C Engine
Rated speed 1000 to 1800
The engine lubrication oil is circulated by a (rpm)
gear-driven pump. The oil is cooled and filtered. A
bypass valve provides unrestricted flow of lubrication Cylinders and 65 degree V-8 65 degree V-12
oil to the engine parts if the engine oil filter elements arrangement
become plugged. Bore 137 mm (5.4 inch)

Cooling System Stroke 152 mm (6 inch)

Compression 11.3:1 or 8.5:1
The standard cooling system has a gear-driven Ratio
pump. The cooling system has two temperature
regulators that regulate the outlet temperature of the Aspiration Naturally Aspirated (NA)
coolant. The temperature depends on the application. Turbocharged Aftercooled (TA) (1)
Jacket water coolant temperature is limited from Total 18 L (1098 in3) 27 L (1648 in3)
93 to 99 °C (200 to 210 °F). displacement

For engines with a Separate Circuit Aftercooler Firing order 1-8-4-3-6-5-7-2 1-4-9-8-5-2-11-
10-3-6-7-12
(SCAC), the air is cooled by a heat exchanger. The
water that cools the air in the heat exchanger is in Rotation Counterclockwise
a circuit that is separate from the jacket water. The (flywheel end)
aftercooler coolant is pumped by an auxiliary water (1) Separate Circuit Aftercooling (SCAC)
pump. The SCAC is required to operate at one of the
following temperatures. The engine rating depends
on the temperature and the application.

• 32 °C (90 °F)
• 54 °C (130 °F)

Engine Service Life

Engine efficiency and maximum utilization of engine
performance depend on adherence to proper
operation and maintenance recommendations. This
includes the use of recommended lubricants, fuels,
and coolants. g00780844
Illustration 20
For the engine maintenance that is required, G3408C Engine design
Refer to the Operation and Maintenance Manual, (A) Inlet valves
“Maintenance Interval Schedule” (Maintenance (B) Exhaust valves
Section). (C) Flywheel
SEBU6883-08 23
Product Information Section
Model Views and Specifications

g01376793
Illustration 21
G3412C Engine design
(A) Inlet valves
(B) Exhaust valves
(C) Flywheel
24 SEBU6883-08
Product Information Section
Product Identification Information

Product Identification
Information
i01505053

Plate Locations and Film

Locations
SMCS Code: 1000; 4450

Engine Identification
Caterpillar engines are identified with serial numbers, Illustration 23
g00123229
with performance specification numbers, and with Typical Serial Number Plate
arrangement numbers. In some of the cases,
modification numbers are used. These numbers The following information is stamped on the Serial
are shown on the Serial Number Plate and the Number Plate: engine serial number, model, and
Information Plate that are mounted on the engine. arrangement number.
Caterpillar dealers need these numbers in order to
determine the components that were included with Information Plate
the engine. This permits accurate identification of
replacement part numbers.

Serial Number Plate

g00708556
Illustration 24
Location of the Information Plate

The Information Plate is located on the top surface

Illustration 22
g00708544 of the right side of the aftercooler.
Location of the Serial Number Plate

The Serial Number Plate is on the left side of the

cylinder block near the front of the engine.

g00361974
Illustration 25
Typical Information Plate
SEBU6883-08 25
Product Information Section
Product Identification Information

The following information is stamped on the Table 2

Information Plate: maximum altitude, high idle, Reference Numbers
horsepower, full load rpm, and other information.
Engine Model

i02135788 Serial Number

Reference Information Arrangement Number

Packaging Arrangement
SMCS Code: 1000; 4450
Turbocharger
Identification of the items in Table 2 may be needed Fuel Filter Element
in order to obtain parts and service. Some of the
Lubrication Oil Filter
numbers are on the engine Serial Number Plate
Element
and/or Information Plate. Locate the information
for your engine. Record the information on the Auxiliary Oil Filter Element
appropriate space in Table 2. Make a copy of this
Air Cleaner Element
list for a record. Retain the information for future
reference. Fan Drive Belt
Alternator Belt
The top level part numbers in the Parts Manual for
the engine are listed with the engine arrangement Capacity of the Lubrication
number. System
Oil type
The packaging arrangement may also be called a
pricing arrangement or a customer arrangement. This Capacity of the Cooling
is the total package with attachments and options System
that are not included in the engine arrangement. Performance Specification
Number
The performance specification can be used by
your Caterpillar dealer with the Technical Marketing Low Idle rpm
Information system. Before the engine leaves the High Idle rpm
factory, the engine performance is tested. Detailed
performance data is recorded. The performance Full Load rpm
specification number can be used for obtaining the Power Rating
data.
26 SEBU6883-08
Operation Section
Lifting and Storage

Operation Section Engine Lifting with a Generator

NOTICE
Lifting and Storage Do not use the engine lifting eyes to remove the en-
gine and generator together.

i01536259 A lifting plate is provided with the package generator

set. Instructions for lifting the package generator set
Product Lifting are stamped on the lifting plate.
SMCS Code: 7000; 7002
Consult your Caterpillar dealer for information
regarding proper fixtures and lifting devices.

Lifting packaged generator sets will not be level if you

lift the unit with a single point lift. A counterweight can
be added between the package frame rails whenever
the application requires frequent relocation of the
unit. For complete information about adding the
counterweight, consult your Caterpillar dealer.

The single point lifting eye is secured from the

Illustration 26
g00103219
NOTICE
Never bend the eyebolts and the brackets. Only load
the eyebolts and the brackets under tension. Remem-
ber that the capacity of an eyebolt is less as the angle
between the supporting members and the object be-
comes less than 90 degrees.
factory before the enclosure is shipped. The correct
orientation of the single point lifting eye will allow you
to look through the eye when you stand at the side of
the enclosure. The lifting eye may stretch when the
package is lifted. This may cause the locking nuts
to loosen. This could cause the lifting eye to swivel.
Ensure that the lifting eye is correctly oriented on the
packaged generator set. Ensure that the lifting eye
is tightened to the correct torque before you lift the
packaged generator set.

When it is necessary to remove a component at an

angle, only use a link bracket that is properly rated for
the weight.

Use a hoist to remove heavy components. Use

an adjustable lifting beam to lift the engine. All
supporting members (chains and cables) should be
parallel to each other. The chains and cables should
be perpendicular to the top of the object that is being
lifted.

Some removals require lifting fixtures in order to

obtain proper balance and safety.

To remove the engine ONLY, use the lifting eyes that

are on the engine.

Lifting eyes are designed and installed for the specific

engine arrangement. Alterations to the lifting eyes
and/or the engine make the lifting eyes and the lifting
fixtures obsolete. If alterations are made, ensure
that proper lifting devices are provided. Consult your
Caterpillar dealer for information regarding fixtures
for proper engine lifting.
SEBU6883-08 27
Operation Section
Lifting and Storage

i02784832

Product Storage
SMCS Code: 7002

If the engine will not be started for several weeks, the

lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder
liner surface, which will increase engine wear which
can reduce engine service life.

To help prevent excessive engine wear, use the

following guidelines:

• Complete all of the lubrication recommendations

that are listed in this Operation and Maintenance
Manual, “Maintenance Interval Schedule”
(Maintenance Section).

• If freezing temperatures are expected, check the

cooling system for adequate protection against
freezing. See the Special Publication, SEBU6400,
“Caterpillar Gas Engine Lubricant, Fuel, and
Coolant Recommendations”.

If an engine is out of operation and if use of the engine

is not planned, special precautions should be made.
If the engine will be stored for more than one month,
a complete protection procedure is recommended.

Your Caterpillar dealer will have instructions for

preparing the engine for extended storage periods.

For more detailed information on engine storage, see

Special Instruction, SEHS9031, “Storage Procedure
for Caterpillar Products”.

Generator Storage
For information on generator storage, see the
literature that is provided by the OEM of the
generator. Consult your Caterpillar dealer for
assistance.
28
Operation Section
Gauges and Indicators
Gauges and Indicators
i01836629
Gauges and Indicators
SMCS Code: 7450
Gauges provide indications of engine performance.
Ensure that the gauges are in good working order.
Determine the normal operating range by observing
the gauges over a period of time.
Noticeable changes in gauge readings can indicate
potential gauge or engine problems. Problems may
also be indicated by gauge readings that change
even if the readings are within specifications.
Determine and correct the cause of any significant
change in the readings. Consult your Caterpillar
dealer for assistance.
Your engine may not have the same gauges or all of
the gauges that are described below.
NOTICE
If no oil pressure is indicated, STOP the engine. The
engine will be damaged from operating without oil
pressure.
Engine Oil Pressure – This gauge
indicates the pressure of the engine oil. This
pressure will be highest after a cold engine
is started. The pressure will decrease as the engine
warms up. The pressure will increase when the
engine rpm is increased. The pressure will stabilize
when the engine rpm and temperature are stable.
For G3400 Engines, the typical oil pressure at rated
rpm is 275 to 600 kPa (40 to 87 psi).
For G3400 Engines at low idle, the typical oil pressure
is 186 to 344 kPa (27 to 50 psi).
If no engine oil pressure is indicated, then stop the
engine.
Oil Filter Differential Pressure – This
gauge indicates the difference in pressure
between the inlet side and the outlet side of
the engine oil filters. As the oil filter elements become
plugged, the pressure will increase. Replace the
engine oil filter elements when the oil filter differential
pressure reaches 103 kPa (15 psi).
SEBU6883-08
Jacket Water Coolant Temperature –
This gauge indicates the temperature of the
engine coolant at the outlet for the jacket
water. The temperature may vary according to the
load. The temperature should never be allowed to
exceed the boiling temperature of the pressurized
cooling system. The operating range is 88 to 98 °C
(190 to 205 °F). Higher temperatures may occur
under certain conditions.
The engine should operate within the normal
temperature range. The sensor for jacket water
coolant temperature must be fully submerged in order
to detect the temperature correctly. If the engine
is operating above the normal temperature range,
perform the following procedure:
1. Reduce the load and/or the engine rpm.
2. Inspect the cooling system for leaks.
3. Determine if the engine must be shut down
immediately or if the engine can be cooled by
reducing the load and/or rpm.
Inlet Manifold Air Temperature – This
gauge indicates the inlet manifold air
temperature to the cylinders.
NOTICE
High inlet manifold air temperature increases the risk
of detonation. Detonation can cause damage to the
engine. Ensure that the aftercooling system is operat-
ing properly.
The inlet manifold air temperature depends on
the engine’s aspiration and the water temperature
regulator for the separate circuit aftercooler (if
equipped). If the maximum temperature is exceeded,
the engine will be unable to provide rated power.
Derating occurs at temperatures that are greater
than the maximum. See Table 3 for maximum
temperatures of different engines.
SEBU6883-08 29
Operation Section
Gauges and Indicators

Table 3 Table 4
Maximum Inlet Manifold Air Temperatures Factors for Converting Service Meter Units
for G3400 Engines to Clock Hours
Aspiration Water Maximum Inlet Operating Speed Factor
Temperature Manifold Air
Regulator Temperature Engines That Are Rated From 1000 RPM to 1400 RPM

Naturally n/a 25 °C (77 °F) (1) 1000 rpm 1.200

aspirated 1200 rpm 1.000
Separate Circuit 32 °C (90 °F) (2) 43 °C (110 °F) 1400 rpm 0.857
Aftercooling
Engines That Are Rated From 1500 RPM to 1800 RPM
Separate Circuit 54 °C (130 °F) (2) 65 °C (150 °F)
Aftercooling 1500 rpm 1.200
(1) This temperature is for an engine at an altitude of 152 m 1600 rpm 1.125
(500 ft) above sea level. A greater temperature or a higher
altitude requires derating. 1800 rpm 1.000
(2) Water inlet to the aftercooler

For example, an engine that is rated at 1800 rpm

Inlet Manifold Air Pressure (TA
has been operating at 1500 rpm. To determine the
Engines) and Inlet Manifold Vacuum
number of clock hours, multiply the number of service
(NA Engines) – For TA engines, this
meter units by the correct factor. In this example, one
gauge indicates the air pressure (turbocharger
service meter unit is equivalent to 1.200 clock hours.
boost pressure) in the air plenum (air inlet manifold)
after the aftercooler. For NA engines, this gauge
Fuel Filter Differential Pressure – This
is the pressure of the inlet manifold vacuum. For
gauge is provided by the customer. This
all engines, this pressure is relative to the load.
gauge indicates the difference in fuel
This pressure may be used for estimating power
pressure between the inlet side and the outlet side
output. Several factors affect the inlet manifold air
of the fuel filter. As the fuel filter element becomes
pressure. All of these factors must be accounted
plugged, the difference in pressure between the two
for when power is estimated from inlet manifold air
sides of the fuel filter increases. Service the fuel
pressure: air restriction, exhaust restriction, coolant
filter when the fuel filter differential pressure reaches
temperature, ambient air temperature, variation of
34 kPa (5 psi).
the fuel, air/fuel ratio, ignition timing, and condition of
the valves.
Air Cleaner Differential Pressure –
This gauge indicates the difference in air
For more information, see the performance curves
pressure between the inlet side and the
in the Engine Performance manual. The manual is
engine side of the air filter element. The pressure
available from your Caterpillar dealer.
is measured from the turbocharger air inlet. As the
air filter element becomes plugged, the difference
Tachometer – This gauge indicates the
in pressure between the two sides of the air
engine rpm.
cleaner element will increase. For optimum engine
performance, replace the air cleaner elements when
the air cleaner differential pressure reaches 2.5 kPa
NOTICE (10 inches of H2O). Maximum air cleaner differential
An overspeed can result in serious damage to the en- pressure is 3.75 kPa (15 inches of H2O).
gine. To help prevent engine damage, never allow the
engine to exceed the rated rpm. Ammeter – This gauge indicates the
amount of charge or discharge in the
Note: The rated rpm is stamped on the engine battery charging circuit. Operation of the
Information Plate. indicator should be to the right side of “0”(zero).

Service Hour Meter – This meter indicates
the total number of service meter units that
have been operated on the engine. Table
4 lists the factors for converting service meter units
to clock hours.
Engine Oil Temperature – This gauge
indicates the engine oil temperature after
the oil has passed through the oil cooler.
The maximum oil temperature at rated rpm and rated
load is 110 °C (230 °F).
30 SEBU6883-08
Operation Section
Gauges and Indicators

The engine oil is cooled by the jacket water. If

the cooling system cannot remove the heat from
the jacket water, the oil will not cool properly. Oil
will degrade rapidly at temperatures above 99 °C
(210 °F). Higher than normal oil temperatures
indicate a problem in the lubrication system and/or
in the cooling system. This can damage these
components: cylinder heads, cylinder liners, pistons,
and crankshaft bearings.
SEBU6883-08 31
Operation Section
Features and Controls

Features and Controls To optimize the inlet air temperature, use ducting and
a heat exchanger. This will help to avoid exposure
to hot air from a generator. For more information,
i02536544 see Application and Installation Guide, LEKQ7250,
“Air Intake”. Consult your Caterpillar dealer for
Performance Parameters assistance.
SMCS Code: 1000
Temperature of the Fuel Supply
Fuel Consumption Changes in the temperature of the fuel supply affects
the air/fuel ratio. Warmer fuel is less dense than cold
Optimum fuel consumption can be obtained by fine fuel. This results in a leaner mixture that causes a
tuning the air/fuel ratio and ignition timing. In order noticeable reduction of power. The recommended
to make fine tuning feasible, the engine must have temperature differential of the air and the fuel is
stable operating parameters. The parameters must 2.8 °C (5 °F).
not exceed the following tolerances.
The maximum fuel temperature depends on the
Table 5 temperature regulator (if equipped) of the aftercooler:
Performance Parameters of the Engine
Parameter Tolerance
• For engines with a 32 °C (90 °F) aftercooler, the
maximum temperature of the air/fuel mixture is
Jacket Water Coolant ± 6 °C (± 10 °F) 43 °C (110 °F).
Temperature
Inlet Manifold Air ± 6 °C (± 10 °F) • For engines with a 54 °C (130 °F) aftercooler, the
Temperature maximum temperature of the air/fuel mixture is
65 °C (150 °F).
Temperature of the Gas ± 6 °C (± 10 °F)
Fuel Energy Content ± 31.6 kJ (± 30 Btu) For more information, see Application and Installation
Guide, LEKQ7260, “Low BTU Engines”. Consult your
Load ± 5% Caterpillar dealer for assistance.

Fuel Supply Pressure

Air/Fuel Ratio
The correct air/fuel ratio is very important for the
following considerations:
• Margin of detonation
• Control of emissions
• Achieving optimum service life for the engine
If the air/fuel ratio is not appropriate for the fuel and
the operating conditions, a failure of the engine may
occur. The service life of the turbocharger, the valves,
and other components may be reduced.
Temperature of the Air Supply
Changes in the temperature of the air supply affects
the air/fuel ratio. In addition to seasonal changes,
the air temperature changes overnight. Control of the
temperature in the engine room will help to maintain
the air/fuel ratio.
Fluctuations of the fuel pressure can change the
air/fuel ratio. For low pressure gas fuel systems
(10 kPa (1.5 psi) to 34.5 kPa (5 psi) fuel pressure into
the regulator on the engine), the maximum fluctuation
that is allowed in the fuel pressure is ± 1.7 kPa
(± 0.25 psi). If more than one engine is using the
fuel supply line, ensure a stable fuel pressure to the
engine by installing a second gas pressure regulator
prior to the gas pressure regulator on the engine.
For high pressure fuel systems, the maximum
fluctuation that is allowed in the fuel pressure is
± 6.9 kPa (± 1 psi).
Gas Pressure Regulator
The gas pressure regulator maintains a pressure
differential between the air and the fuel that is
supplied to the carburetor. Set the pressure of the
fuel supply according to the instructions in Systems
Operation/Testing and Adjusting. The gas pressure
regulator will maintain the pressure differential in
response to changes in the air pressure.
32 SEBU6883-08
Operation Section
Features and Controls

A water manometer is used to measure the pressure

differential. This measurement is taken when the
engine is operating at high idle rpm with no load.
When a load is applied, the fuel pressure will
usually decrease by approximately 0.25 to 0.5 kPa
(1 to 2 inches of H2O). If the performance of the
gas pressure regulator is erratic, the gas pressure
regulator may require service.

Throttle Angle and Exhaust Bypass

(Wastegate)
A throttle angle of approximately 70 degrees is
recommended for full load operation.

The following factors affect the angle of the throttle:

• LHV of the fuel

• Air/fuel ratio
• Setting of the exhaust bypass (wastegate)
• Altitude
• Ignition timing
After the desired exhaust emissions are achieved,
the exhaust bypass is adjusted in order to achieve
full load operation with the desired throttle angle.
Excess boost generates back pressure in the exhaust
manifold. This raises pumping losses which increase
fuel consumption.

Ensure that the angle of the throttle plate is properly

set. This will maintain the margin for detonation. This
will also enable the engine to accept load changes
without lugging down and shutting off.
SEBU6883-08 33
Operation Section
Features and Controls

i02791455

Sensors and Electrical

Components
SMCS Code: 1900; 7400

g01394637
Illustration 27
Left side and rear views of a typical G3408 or G3412 Engine
(1) Detonation sensor (2) Speed sensor

g01394638
Illustration 28
Right side and front of a typical G3408 or G3412 Engine
(3) Nitrous oxide sensor or oxygen sensor (4) Inlet manifold pressure sensor
(1) Detonation sensor (5) Speed/timing sensor
34
Operation Section
Features and Controls
g01394803
Illustration 29
Partial view of the top of a typical G3408 orG3412 Engine
(6) Inlet manifold temperature sensor
The sensors provide signals to the control module.
The control module uses the signals in order to
provide the signals to the transformers at the
appropriate time.
(1) Detonation sensors
Detonation sensors produce voltage signals that are
proportional to the level of detonation. The control
module uses the signals from the detonation sensors
in order to determine the level of detonation. To
eliminate detonation, the control module will retard
the ignition timing.
(2) Speed sensor
The engine speed sensor provides a signal to the
electronic ignition system that indicates the speed of
the engine. The electronic ignition system uses the
signal in order to govern the speed of the engine.
The speed sensor (magnetic pickup) is installed in
the left side of flywheel housing.
(3) Nitrous oxide sensor (if equipped)
The nitrous oxide sensor is located in the outlet for
the exhaust system. The sensor monitors the amount
of nitrous oxide in the exhaust. If the level of nitrous
oxide is greater than the level that is programmed
into the engine control module (ECM), the ECM will
adjust the engine so that the level is acceptable.
(3) Oxygen sensor (if equipped)
The oxygen sensor is located in the outlet for the
exhaust system. The oxygen sensor monitors the
amount of oxygen in the exhaust.
(4) Inlet manifold pressure sensor
SEBU6883-08
The control module uses the signal from the inlet
manifold pressure sensor in order to determine the
engine load.
(5) Speed/timing sensor
The speed/timing sensor provides information to the
control module about the position of the crankshaft
and the engine rpm. The control module uses the
information in order to determine the ignition timing.
(6) Inlet manifold temperature sensor
The inlet manifold temperature sensor provides a
signal to the EIS that indicates the temperature of the
air/fuel mixture in the inlet manifold. The EIS uses the
information in order to control the air/fuel ratio.
i02798932
Alarms and Shutoffs
SMCS Code: 7400
This section contains some general information about
the function of typical engine protective devices.
The operation of all alarms and shutoffs utilize
components which are actuated by a sensing unit.
The alarms and shutoffs are set at critical operating
temperatures, pressures, or speeds in order to
protect the engine from damage.
Alarms function in order to warn the operator
when an abnormal operating condition occurs.
Shutoffs function in order to shut down the engine
when a more critical abnormal operating condition
occurs. The shutoffs help to prevent damage to the
equipment.
Shutoffs may cause unburned gas to remain in the
air inlet and in the exhaust manifold.
Unburned gas in the air inlet and exhaust system
may ignite when the engine is started. Personal
injury and/or property damage may result.
Before starting an engine that may contain un-
burned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging unburned gas in the “Starting the Engine”
section.
If an engine protective device shuts off the engine,
always determine the cause of the shutoff. Make
the necessary repairs before attempting to start the
engine.
SEBU6883-08 35
Operation Section
Features and Controls

Become familiar with the following information:

• Types of the alarm and shutoff controls

• Locations of the alarm and shutoff controls
• Conditions which cause each control to function
• Resetting procedure that is required before starting
the engine

On G3400 Engines, protective devices are available

for the following faults:

• Low oil pressure

• High coolant temperature
• Overspeed
• Low coolant level
Further protection is supplied by an emergency stop
button.

Three basic protection systems are available:

• Self-powered shutoff
• Automatic start/stop system
• Customer supplied shutoff
Note: For an energize-to-shutoff system, the gas
shutoff valve must be energized to shut off gas to
the engine. For an energize-to-run system, the gas
shutoff valve must be energized in order to supply
gas to the engine.

The self-powered system can be used with an

air starting motor or an electric starting motor. An
energize-to-shutoff gas valve and an instrument
panel are required for this system.

Power for the automatic start/stop system is supplied

by an external 24 volt electrical source. The automatic
start/stop system can be used with an air starting
motor or an electric starting motor. An energize-to-run
gas valve and one of these controls are required:

• Automatic start/stop switchgear

• Engine control logic
For the customer supplied shutoff system, the
customer must supply all of the wiring and the
shutoffs. This includes the emergency stop button
and wiring.

The features of the shutoff systems are listed in Table

6.
36 SEBU6883-08
Operation Section
Features and Controls

Table 6
G3400 Engine Protection Systems
Type of System Shut Down
Item Setting Limits
Self-Powered Automatic Start/Stop Customer Supplied (1)
High jacket water coolant Yes Yes Yes 105 °C (221 °F)
temperature
Low oil pressure (high rpm) Yes Yes Yes 275 kPa (40 psi)
Low oil pressure (low rpm) 100 kPa (15 psi)
Overspeed (1800 rpm) No (2) Yes Yes 2160 RPM
Overspeed (1400 rpm) 1680 RPM
High inlet manifold air No No Yes (3) 43 °C (110 °F)
temperature
32 °C (90 °F)
High inlet manifold air 66 °C (150 °F)
temperature
54 °C (130 °F)
Emergency stop Yes Yes Yes N/A
(1) The customer is responsible for supplying the shutoffs and the wiring.
(2) Overspeed protection is available as an option.
(3) The customer is responsible for supplying the protection for either high inlet manifold temperature or high aftercooler water temperature.

i02791234 Control Panel for Stopping

Control Panel
SMCS Code: 7451

Your engine may be equipped with one of the

following control panels.

g01394329
Illustration 30
(1) “WARNING” indicator
(2) “SHUTDOWN” indicator
(3) “POWER ON” indicator
(4) “EMERGENCY STOP” button
(5) “DIAGNOSTIC RESET” switch
SEBU6883-08
The amber “WARNING” indicator (1) flashes or the
amber “WARNING” indicator illuminates continuously
in order to indicate the occurrence of an abnormal
operating condition. A warning is not severe enough
to cause a shutdown. However, this signifies a
serious problem. If a warning occurs, a diagnostic
code for the condition is logged in the ECM. Correct
the cause of the warnings as soon as possible in
order to avoid problems with operation.
The red “SHUTDOWN” indicator (2) illuminates
continuously when an adverse operating condition
causes a shutdown. A diagnostic code for the
condition is logged in the ECM. If the engine is shut
down due to parameters that are out of acceptable
limits, the red indicators on the“SHUTDOWN”
indicator will also illuminate.
The green “POWER ON” indicator (3) illuminates
continuously when power is supplied to the control
panel.
The red “EMERGENCY STOP” button (4) is used to
stop the engine in an emergency situation. When the
button is pressed, the status control module shuts off
the fuel via the gas shutoff valve. The module also
terminates the ignition. The “EMERGENCY STOP”
button must be reset before the engine will start.
The “DIAGNOSTIC RESET” switch (5) is used
to clear diagnostic codes from the engine control
module (ECM). The switch can not clear individual
codes. Use of the switch will clear all of the codes that
are active in the ECM. Do not clear the codes until
the problems that caused the codes are addressed.
Remote Control Panel (Status)
This section contains some general information about
the Remote Control Panel (Status). For more detailed
information, see these publications:
• Systems Operation/Testing and Adjusting,
SENR6420, “Control Panel (Status-Timing)”
• Electronic Troubleshooting, SENR6535, “G3400
Engines”.
37
Operation Section
Features and Controls
g01395223
Illustration 31
(6) “WARNING” indicator
(7) “SHUTDOWN” indicator
(8) “POWER ON” indicator
(9) “DIAGNOSTIC RESET” switch
(10) Engine control switch
(11) Status control module
(12) “EMERGENCY STOP” button
The yellow “WARNING” indicator (6) flashes or stays
lighted in order to indicate the occurrence of an
abnormal operating condition. A warning is not severe
enough to cause a shutdown. However, this signifies
a serious problem. If a warning occurs, a diagnostic
code for the condition is logged in the engine control
module. Correct the cause of the warnings as soon
as possible in order to avoid problems with operation.
The red “SHUTDOWN” indicator (7) illuminates
continuously when an adverse operating condition
causes a shutdown. A diagnostic code for the
condition is logged in the engine control module. If
the engine is shut down due to parameters that are
out of acceptable limits, the red indicators on the
status control module (11) will also illuminate.
“POWER ON” indicator (8) illuminates continuously
when power is supplied to the control panel.
“DIAGNOSTIC RESET” switch (9) is a toggle switch
that is used to clear diagnostic codes from the engine
control module. The switch cannot clear individual
codes. Use of the switch will clear all codes that are
active in the engine control module. Do not clear the
codes until the problems that caused the codes
are addressed.
Engine control switch (10) is used to control starting
the engine and stopping the engine.
38 SEBU6883-08
Operation Section
Features and Controls

Status control module (11) has several engine

monitoring and control functions.

“EMERGENCY STOP” button (12) is used to stop the

engine in an emergency situation. When the button is
pressed, the status control module shuts off the fuel
via the gas shutoff valve. The module also terminates
the ignition. The “EMERGENCY STOP” button must
be reset before the engine will start.

Status Control Module

The status control module receives information from
the following sources:

• The operator
• Magnetic pickups
• Transducers (oil pressure and water temperature)
g01395226
• Optional remote sources Illustration 32
(13) Liquid crystal display (LCD)
The basic performance of the status control module (14) Switch
includes the following functions: (15) “LOW OIL PRESSURE” indicator
(16) “EMERGENCY STOP” indicator
(17) “AUXILIARY SHUTDOWN” indicator
When the status control module receives a signal to (18) “HIGH COOLANT TEMPERATURE” indicator
start the engine, the module enables fuel to flow to (19) “OVERSPEED” indicator
the engine. The module activates the starting motor. (20) “OVERCRANK” indicator
After the rpm for crank termination is achieved, the
module deactivates the starting motor. Liquid Crystal Display (LCD) – Symbols for the
following parameters are located under LCD (13).
When the status control module receives a signal to The LCD provides a digital display of the status of
stop the engine, the module shuts off the fuel. The these parameters. When the status of a parameter is
module sends a signal to the engine control module. displayed, an arrow at the bottom of the LCD points
The engine control module terminates the ignition. the corresponding symbol. The display can be in
metric units or English units.

Hour meter – When the arrow points to

this symbol, the hours of engine operation
are displayed.

Engine speed – When the arrow points to

this symbol, the engine rpm is displayed.

System battery voltage – When the arrow

points to this symbol, the voltage of the
electrical system’s battery is displayed.

Engine oil pressure – When the arrow

points to this symbol, the engine oil
pressure is displayed.

Engine coolant temperature – When

the arrow points to this symbol, the engine
coolant temperature is displayed.
SEBU6883-08 39
Operation Section
Features and Controls

The parameters are displayed sequentially. To lock

the display onto one of the parameters, press switch
(14). To resume the sequential display, press the
switch again.
The LCD is also used to display diagnostic codes.
A diagnostic indication signifies that the system
has detected the failure of components that are
associated with the status control module. When a
diagnostic code is displayed, the arrow that indicates
the display of the parameters will be missing. A
flashing “DIAG” will be displayed. If more than one
diagnostic code is present, the diagnostic codes will
be displayed in sequence.
To clear the diagnostic codes from the LCD, turn the
engine control switch to the “OFF/RESET” position.
For information on diagnostic codes, see these
publications:
• Systems Operation/Testing and Adjusting,
SENR6420, “Control Panel (Status-Timing)”
• Electronic Troubleshooting, SENR6535, “G3400
Engines”.
“HIGH COOLANT TEMPERATURE” –
If the coolant temperature exceeds the
setpoint, the fuel will be shut off. Indicator
(18) will flash.
“OVERSPEED” – If the engine rpm
exceeds the setpoint for overspeed, the fuel
and the ignition will be shut off. Indicator
(19) will flash.
“OVERCRANK” – If the engine fails to
start within a programmed amount of
time or if the number of cranking’s (crank
cycle) is exceeded, the status control module will
deactivate the starting sequence. Indicator (20) will
flash. The engine control switch must be turned to
the “OFF/RESET” position before another attempt to
start the engine can be made.
Engine Control Switch

The status control module has six indicators

(Illustration 32) that indicate engine shutdowns. The
shutdowns that are associated with the indicators are
described below.

“LOW OIL PRESSURE” – There are two

setpoints for low oil pressure. The setpoints
depend on the engine rpm. One setpoint
is for engine rpm that is below the oil step speed
setting. The other setpoint is for engine rpm that is
above the oil step speed setting. If the engine oil
pressure decreases below the setpoint, the fuel to Illustration 33
g00307929
the engine will be shut off. Indicator (15) will flash.
Engine control switch in the “OFF/RESET” position

Note: A verify button for overspeed is located on the
back of the status control module. This enables a test
of the overspeed protection system to be performed.
See Systems Operation/Testing and Adjusting,
SENR6420, “Control Panel (Status-Timing)” for
information on the service procedure.
“EMERGENCY STOP” – Indicator (16) will
flash if the “EMERGENCY STOP” button is
used to stop the engine.
Note: Do not use the coolant temperature sensor
to monitor the operation of jacket water heaters (if
equipped).
“AUXILIARY SHUTDOWN” indicator (17) indicates
that an external request was used to stop the engine.
If the auxiliary shutdown is not used, the “AUXILIARY
SHUTDOWN” indicator can be used as a spare
indicator.
The engine control switch is a rotary switch that has
four positions:
• “OFF/RESET”
• “AUTO”
• “MAN. START”
• “COOLDOWN/STOP”
Note: Only the indicators on the status control
module are reset when the engine control switch
is turned to the “OFF/RESET” position. Diagnostic
codes must be cleared with the “DIAGNOSTIC
RESET” switch (Illustration 33).
40 SEBU6883-08
Operation Section
Features and Controls

“OFF/RESET” – When the engine control switch is

turned to this position (12 o’clock), the fault indicators
on the status control module are reset and the engine
shuts down immediately. The power to the engine
control module and the status control module is shut
off. This method is not recommended for normal
stopping.

“AUTO” – When the engine control switch is in this

position (3 o’clock), the system is configured for
remote operation. When the remote start/stop initiate
contact closes, the engine will start. When the remote
start/stop initiate contact opens, the engine will shut
down. If the cooldown cycle is programmed, the
engine will operate for the cooldown period before
the engine stops.

“MAN. START” – When the engine control switch

is turned to this position (6 o’clock), the engine will
start. The engine will continue to operate when the
switch is in this position. However, if a setpoint for a
shutdown is exceeded, the engine will shut down. Illustration 34
g01400036

(21) Control module

“COOLDOWN/STOP” – This is the preferred (22) Manifold air pressure sensor
method for normal stopping. When the engine control (23) NOx sensor
switch is turned to this position (9 o’clock), the (24) Speed sensor (magnetic pickup)
engine will continue to operate until a programmable (25) Fuel valve
cooldown cycle has elapsed. The cooldown cycle
can be programmed for a 0 to 30 minute period. The The control module for the air/fuel ratio control is
default setting is five minutes. shown below.

Electronic Control Group for the Air/fuel

Ratio
The engine electronic control group for the air/fuel
ratio is a digital control for use with low emission
engines that use natural gas with one gas pressure
regulator and a carburetor. This system can be
configured in the field with the keypad that is on the
control module. The settings of the control module
and the system diagnostics are designed to control
the fuel system in order to maintain operation at
reduced emission levels. The system consists of five
basic components:

• Control module
• Inlet manifold pressure sensor
• NOx Sensor
g01399099
Illustration 35
• Speed sensor
(26) “POWER”
(27) “ALARM”
• Fuel valve (28) Display
(29) Keypad
SEBU6883-08 41
Operation Section
Features and Controls

The inlet manifold air pressure is a measure of engine

load. The measure of NOx in the engine exhaust is
one measure of the exhaust emissions. The engine
speed is monitored by a speed sensor. The control
uses the information from these inputs in order to
determine the setpoint of the desired emissions level.
The control uses the information from these inputs in
order to maintain engine operation at that setpoint.

For more information about the controls for the air/fuel

ratio, refer to the following publications:Systems
Operation, KENR5186, “G3408C and G3412C
Engines Air/Fuel Ratio Control (NOx Feedback)”
and Troubleshooting, RENR5916, “Air/Fuel Ratio
Control”.

i00973195

Engine Speed Governing

SMCS Code: 1908

A variety of governors and actuators are available

for different engine applications. For information on
governors and actuators, see the Service Manual.
Consult your Caterpillar dealer for assistance.
42
Operation Section
Engine Starting
Engine Starting
i02142937
Before Starting Engine
SMCS Code: 1000; 1400; 1450
Note: Certain procedures are required before an
engine is started for the first time. Refer to the Special
Instruction, REHS0371, “Installation and Initial
Start-Up Procedure for G3300 and G3400 Engines”.
Perform the required daily maintenance and other
periodic maintenance before starting the engine. This
can prevent major repairs at a later date. Refer to the
Operation and Maintenance Manual, “Maintenance
Interval Schedule” (Maintenance Section).
Walk-Around Inspection
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
unwarranted.
To obtain maximum service life for your engine, make
a thorough inspection before starting the engine.
Make a walk-around inspection of the installation.
Look for items such as oil or coolant leaks, loose
bolts and trash buildup. Remove any trash. Make
repairs, if necessary.
• Inspect the drive belts for cracks and wear.
• The guards must be in the proper place. Repair
damaged guards or replace missing guards.
• Ensure that the areas around the rotating parts are
clear.
Air Inlet System
Unburned gas in the air inlet and exhaust system
may ignite when the engine is started. Personal
injury and/or property damage may result.
Before starting an engine that may contain un-
burned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging unburned gas in the “Starting the Engine”
section.
SEBU6883-08
• Ensure that the air inlet piping and the air filters
are in place.
• Ensure that all clamps and connections are secure.
• Inspect the air cleaner service indicator (if
equipped). Service the air cleaner filter element
when the yellow diaphragm enters the red zone, or
the red piston locks in the visible position.
• Inspect flexible piping for cracks and leaks.
Cooling System
• Inspect the cooling system for leaks or loose
connections. Inspect the condition of all the hoses
and pipes for the cooling system. Ensure that the
connections are properly clamped.
• Inspect the water pumps for evidence of leaks.
• Check the coolant level. Add coolant, if necessary.
For information on the proper coolant to use, see
this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” (Maintenance
Section).
• For engines with separate circuit aftercooling, open
the water supply.
Driven Equipment
• Check the oil levels of the driven equipment.
Perform any maintenance that is required for the
driven equipment. Refer to the literature that is
provided by the OEM of the driven equipment.
• If the engine is equipped with a clutch, ensure that
the clutch is disengaged.
• For generator set engines, ensure that the main
circuit breaker is open.
Electrical System
Inspect the wiring for the following conditions:
• Loose connections
• Wiring that is worn or frayed
Inspect the gauge panel and the control panel
for good condition. Reset any shutoff or alarm
components.
SEBU6883-08 43
Operation Section
Engine Starting

Fuel System Starting System

NEVER use a flame to check for gas leaks. Use a
gas detector.
An open flame can ignite mixtures of air and fuel.
This will cause explosion and/or fire which could
result in severe personal injury or death.
• Check the fuel system for leaks with a gas detector.
• Inspect the fuel lines for loose fittings. Ensure that
the fuel lines are properly clamped.
• Ensure that the fuel is supplied to the engine at the
correct pressure for the engine.
Lubrication System
Note: If the engine is equipped with a system for
external support, prepare the system before starting
the engine. Ensure that all of the systems for engine
support are enabled. Perform all prestart checks for
the control system.
Air Starting Motor
• Drain moisture and sediment from the air tank and
from any other air piping.
• Check the oil level in the lubricator. Keep the
lubricator at least half full. Add oil, if necessary.
For temperatures above 0 °C (32 °F), use a
nondetergent 10W oil. For temperatures below
0 °C (32 °F), use air tool oil.
• Check the air pressure for starting. The air starting
motor requires a minimum of 690 kPa (100 psi).
The maximum allowable air pressure is 1030 kPa
(150 psi). Open the air supply valve.

Electric Starting Motor

• Disconnect any battery chargers that are not
protected against the high current drain that is
created when the electric starting motor engages.

Inspect the wiring, the electrical cables, and the

battery for the following conditions:

• Loose connections
• Wires that are worn or frayed
g00760044
Illustration 36
Oil level gauge (dipstick) • Corrosion
(1) “ADD” mark
(2) “FULL” mark

NOTICE
Excessive engine oil will increase oil consumption and
result in excessive deposits in the combustion cham-
ber. Do not overfill the engine with oil.

• Check the engine crankcase oil level. Maintain the

oil level between the “ADD” and “FULL” marks
on the “ENGINE STOPPED” side of the oil level
gauge. For information on the proper oil to use, see
this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” (Maintenance
Section).

• Check for leaks at the following components:

crankshaft seals, crankcase, oil filters, oil gallery
plugs, sensors, and valve cover.

• Inspect the tubes, and the clamps on the crankcase

breathers.
44
Operation Section
Engine Starting
i01857649
Cold Weather Starting
SMCS Code: 1000; 1250; 1450; 1453; 1456; 1900
Note: Oil pan immersion heaters are not
recommended for heating the lube oil. To ensure the
compatibility of the components, only use equipment
that is recommended by Caterpillar.
A jacket water heater is required for starting in
temperatures as low as 0 °C (32 °F). The jacket
water heater can maintain the water temperature at
approximately 32 °C (90 °F). The heated water will
help to keep the oil in the engine block warm enough
to flow when the engine is started. A jacket water
heater is required for starting when the temperature
is less than 16 °C (60 °F).
For air starting motors, a larger volume of starting
air and/or a higher air pressure may be necessary in
order to start the engine at colder temperatures.
For electric starting, extra battery capacity may be
necessary.
Consult your Caterpillar dealer for more information
on the starting aids that are available for cold weather
starting.
i02799025
Starting the Engine
SMCS Code: 1000; 1450
Engine exhaust contains products of combustion
which may be harmful to your health. Always start
and operate the engine in a well ventilated area
and, if in an enclosed area, vent the exhaust to the
outside.
NOTICE
For initial start-up of a new or rebuilt engine, and for
start-up of an engine that has been serviced, make
provision to shut the engine off should an overspeed
occur. This may be accomplished by shutting off the
fuel supply and/or the ignition to the engine.
SEBU6883-08
Unburned gas in the air inlet and exhaust system
may ignite when the engine is started. Personal
injury and/or property damage may result.
Before starting an engine that may contain un-
burned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging unburned gas in the “Starting the Engine”
section.
Do not start the engine or move any of the controls
if there is a “DO NOT OPERATE” warning tag or
similar warning tag attached to the start switch or to
the controls.
Ensure that no one will be endangered before the
engine is started and when the engine is started.
Perform the procedures that are described in this
Operation and Maintenance Manual, “Before Starting
Engine” (Operation Section).
Purging Unburned Gas
The following events cause unburned gas to remain
in the air inlet and in the exhaust manifold:
• Emergency stop
• Engine overspeed
• Unsuccessful successive attempts to start the
engine
Unburned gas may remain in the air inlet and exhaust
system after several unsuccessful attempts to start
the engine. The unburned gas may increase to a
concentration that may ignite during a successive
attempt to start the engine.
Perform the following procedure in order to purge
the unburned gas:
1. Turn the manual gas shutoff valve to the CLOSED
position.
2. Disable the ignition by disconnecting one of the
wires that is labelled “M200” from the emergency
stop button.
3. Turn the engine control switch to the START
position. Crank the engine for one full crank cycle
in order to purge the unburned gas.
4. Enable the ignition by connecting the wire that
was disconnected in Step 2.
SEBU6883-08
5. Turn the manual gas shutoff valve to the OPEN
position.
6. Continue with your previous procedure.
Operation of the Generator Set
Control Panel
For information on operation for a specific generator
set control panel, refer to the Operation and
Maintenance Manual for the generator and the
control panel.
Automatic Starting
When the engine is in the AUTOMATIC mode, the
engine can start at any moment. To avoid personal
injury, always remain clear of the the engine when
the engine is in the AUTOMATIC mode.
If the engine control switch is in the “AUTO” position,
the engine will automatically start when the remote
start/stop initiate contact closes. The engine will
accelerate to rated rpm when the oil pressure is
sufficient.
Manual Starting
1. Ensure that fuel is supplied to the engine. Ensure
that no gas is leaking.
2. Ensure that the driven equipment is unloaded.
a. For generator set engines, open the main
circuit breaker.
b. For industrial engines, unload the compressor
or pump. Disengage the clutch (if equipped).
Place the transmission and/or other
attachments for the power take-off in
NEUTRAL.
Note: Before starting an industrial engine, move the
governor control lever to the position for 1/2 of rated
rpm.
NOTICE
Do not engage the starting motor when flywheel is
turning. Do not start the engine under load.
If the engine fails to start within 30 seconds, release
the starter switch or button and wait two minutes to
allow the starting motor to cool before attempting to
start the engine again.
45
Operation Section
Engine Starting
3. The method that is used for starting depends on
the equipment:
a. For electric starting, press the “START” button
or turn the start/stop switch to the “START”
position.
g00523569
Illustration 37
“START” valve on an air starting motor
b. For starting with air, push the “START” valve.
Release the valve as soon as the engine starts.
Shut off the air supply to the starting motor.
Note: After starting an industrial engine, move the
governor control lever to the position for low idle rpm.
4. Allow the engine to idle for three to five minutes.
The engine speed should stabilize at low idle rpm.
Check all of the pressure gauges. Inspect the
engine for leaks and listen for unusual noises.
When all systems are normal, the rpm may be
increased.
Starting Failure
If the engine fails to start after cranking for 30
seconds, stop cranking. Perform the following
procedure:
1. Turn the start switch to the “OFF” position.
2. Turn the gas supply OFF.
3. Allow the starting motor to cool for two minutes.
Crank the engine for approximately 15 seconds
in order to evacuate any unburned gas from the
engine and the exhaust system.
4. Allow the starting motor to cool for two minutes.
Turn the gas supply ON. Repeat the starting
procedure.
46
Operation Section
Engine Starting
i02070307
Starting with Jump Start
Cables
SMCS Code: 1000; 1401; 1402; 1900
Improper jump start cable connections can cause
an explosion resulting in personal injury.
Prevent sparks near the batteries. Sparks could
cause vapors to explode. Do not allow jump start
cable ends to contact each other or the engine.
If the installation is not equipped with a backup
battery system, it may be necessary to start the
engine from an external electrical source.
Many batteries which are considered unusable are
still rechargeable. After jump starting, the alternator
may not be able to fully recharge batteries that
are severely discharged. The batteries must be
charged to the proper voltage with a battery charger.
For information on testing and charging, refer to
the Special Instruction, SEHS7633, “Battery Test
Procedure”.
NOTICE
Using a battery source with the same voltage as the
electric starting motor. Use ONLY equal voltage for
jump starting. The use of higher voltage will damage
the electrical system.
Do not reverse the battery cables. The alternator can
be damaged. Attach ground cable last and remove
first.
When using an external electrical source to start the
engine, turn the generator set control switch to the
“OFF” position. Turn all electrical accessories OFF be-
fore attaching the jump start cables.
Ensure that the main power switch is in the OFF posi-
tion before attaching the jump start cables to the en-
gine being started.
1. Turn the start switch on the stalled engine to the
OFF position. Turn off all accessories.
2. Connect one positive end of the jump start cable
to the positive cable terminal of the discharged
battery. Connect the other positive end of the jump
start cable to the positive cable terminal of the
electrical source.
SEBU6883-08
3. Connect one negative end of the jump start cable
to the negative cable terminal of the electrical
source. Connect the other negative end of the
jump start cable to the engine block or to the
chassis ground. This procedure helps to prevent
potential sparks from igniting combustible gases
that are produced by some batteries.
4. Charge the batteries. The engine will not continue
to run after starting if the batteries have not been
charged.
5. Start the engine.
6. Immediately after the stalled engine is started,
disconnect the jump start cables in reverse order.
Refer to the Electrical Schematic for your engine.
Consult your Caterpillar dealer for more information.
i01028507
After Starting Engine
SMCS Code: 1000
For new installations and engines that are recently
rebuilt, carefully monitor the engine in order to detect
any unusual engine performance.
The engine rpm can be increased from low idle rpm
to rated rpm after one minute.
It may be necessary to apply some load in order to
attain normal operating temperatures. The operator
can ramp the load manually. For automatic loading,
programmable logic control can be used.
Engaging the Driven Equipment
Generator Set Engines
1. Increase the engine speed to rated rpm.
2. Ensure that the gauges are in the normal ranges
for the engine rpm.
3. Close the main circuit breaker in order to apply
the load.
Industrial Engines
1. Increase the engine rpm. Ensure that the gauges
are in the normal ranges for the engine rpm.
2. Engage the driven equipment with no load on the
driven equipment.
3. Increase the engine rpm and the load, as needed.
SEBU6883-08 47
Operation Section
Engine Operation

Engine Operation For example, an engine is operating at 20 percent

of the rated torque. The engine may be operated at
this load factor for a maximum of one-half hour. After
i02061036 the one-half hour, operate this engine for at least two
hours at a load factor of more than 70 percent.
Engine Operation
To keep engine maintenance at a minimum, follow
SMCS Code: 1000 the guidelines that are listed in Table 7.

Proper operation and maintenance are key factors in Table 7

attaining the maximum service life and economy for Time Limits For Low Load Operation
the engine. Follow the instructions in this Operation
and Maintenance Manual in order to minimize Engine Torque NA Engines TA Engines
operating costs and maximize the service life of the 0 to 30% 1/2 hour 1/2 hour
engine.
31 to 60% 2 hours 2 hours
Observe the gauges frequently while the engine is 61 to 70% 24 hours Continuous(1)
operating. Record the data from the gauges in a log
regularly. Compare the data to the specifications 71 to 100% Continuous Continuous(1)
for normal engine operation. Comparing the data (1) For continuous operation of TA engines, the manifold air
over time will help to detect changes in engine pressure should be greater than the atmospheric pressure.
performance.

Investigate any significant change in the gauge

readings. Monitor the engine operation and take
action when discrepancies are found.

Operating the Engine and the

Driven Equipment
Check the gauges and the driven equipment
frequently while the engine is operating under a load.
The engine can be operated for extended periods
of time at full load.

Partial Load Operation

Extended operation at low idle or at a reduced load
will cause increased oil consumption and carbon
buildup in the cylinders. Carbon buildup results in
the following effects:

• Power loss
• Poor performance
• Accelerated wear of components
Caterpillar Engines can be operated at very light
loads (torques) for limited times with no harmful
effects. Table 7 lists the limits for hours of operation
at various torques.

After the time limit for reduced load operation has

expired, operate the engine for a minimum of two
hours at a torque that is more than 70 percent.
48
Operation Section
Engine Stopping
Engine Stopping
i02143005
Emergency Stopping
SMCS Code: 1000; 7418
NOTICE
Emergency shutoff controls are for EMERGENCY use
ONLY. DO NOT use emergency shutoff devices or
controls for normal stopping procedure.
Ensure that any system that provides external
support to the engine is secured after the engine is
stopped.
NOTICE
Do not start the engine until the problem necessitating
the emergency stop has been located and corrected.
Pressing the Emergency Stop Button may cause
unburned gas to remain in the air inlet and in the
exhaust manifold.
Unburned gas in the air inlet and exhaust system
may ignite when the engine is started. Personal
injury and/or property damage may result.
Before starting an engine that may contain un-
burned gas, purge the unburned gas from the air
inlet and exhaust system. Refer to the topic on
purging unburned gas in the “Starting the Engine”
section.
Emergency Stop Button
g00520710
Illustration 38
Emergency stop button on the junction box
SEBU6883-08
For the junction box, the emergency stop button is in
the OUT position for normal engine operation. For an
emergency stop, push the emergency stop button.
The button must be reset before the engine can be
started.
To reset the button, turn the button clockwise. The
spring-loaded button will return to the OUT position.
i01020551
Manual Stop Procedure
SMCS Code: 1000; 7418
NOTICE
Stopping the engine immediately after the engine has
been operating under a load can result in overheating
and accelerated wear of the engine components.
Allow the engine to gradually cool before stopping the
engine.
Note: Remove the load at a rate that will avoid
detonation.
1. Disengage the driven equipment.
a. For generator set engines, open the main
circuit breaker.
b. For industrial engines, unload the compressor
or pump. Disengage the clutch (if equipped).
Place the transmission and/or other
attachments for the power take-off in
NEUTRAL.
Note: Extended idling can cause excessive oil
consumption and related problems. See this
Operation and Maintenance Manual, “Engine
Operation” topic (Operation Section).
2. Reduce the engine rpm to low idle.
3. Operate the engine at low idle rpm for a cool down
period.
If the engine has been operated at a low load,
operate the engine at low idle for approximately
30 seconds before stopping the engine.
If the engine has been operated at a high load,
operate the engine at low idle for three to five
minutes before stopping the engine.
4. To stop the engine, shut off the fuel supply.
The engine will coast to a stop. Ensure that any
system that provides external support to the engine
is secured after the engine is stopped.
SEBU6883-08 49
Operation Section
Engine Stopping

i02416955

After Stopping Engine

SMCS Code: 1000

• Check the engine crankcase oil level. Maintain the

oil level between the “ADD” and “FULL” marks
on the “ENGINE STOPPED” side of the oil level
gauge.

• If necessary, perform minor adjustments. Repair

any leaks and tighten loose bolts.

• Note the service hour meter reading. Perform the

maintenance that is scheduled in this Operation
and Maintenance Manual, “Maintenance Interval
Schedule” (Maintenance Section).

NOTICE
Follow the guidelines for antifreeze/coolant mixtures
that are recommended in this Operation and Mainte-
nance Manual, “Refill Capacities and Recommenda-
tions” topic. Failure to do so can cause engine dam-
age.

• Allow the engine to cool. Check the coolant level.

• If freezing temperatures are expected, check the
coolant for protection against freezing. The cooling
system must be protected against freezing to the
lowest expected outside temperature. Add the
proper coolant/water mixture, if necessary.

• Perform all required periodic maintenance on all

driven equipment. Refer to the instructions that are
provided by the OEM of the driven equipment.
50 SEBU6883-08
Maintenance Section
Refill Capacities

Maintenance Section Lubricant Capacities

The capacity of the lubrication system includes the
capacity of the oil filters that are installed at the
Refill Capacities factory.

Optional auxiliary filters require additional oil.

i02524752
-
Refill Capacities and
Recommendations
SMCS Code: 1348; 1395; 7560

Lubrication System
Lubricant Recommendations
Due to significant variations in the quality and in
the performance of commercially available oils,
Caterpillar makes the following recommendations:

• Cat NGEO (Natural Gas Engine Oil) g00848238

Illustration 39
• Cat NGEO EL350 (Natural Gas Engine Oil) Oil pan for G3400CEngines
(1) Standard oil pan
The proper SAE viscosity grade of oil is determined
by the minimum ambient temperature during Table 9
cold engine start-up, and the maximum ambient Approximate Refill Capacity for the G3408C
temperature during engine operation. To determine Engine Lubrication System
the oil viscosity that is required for starting a cold
soaked engine, refer to the minimum temperature in Compartment or System Liters US Gal
Table 8. To select the oil viscosity for operation at Engine crankcase 150 39
the highest anticipated ambient temperature, refer Standard oil pan
to the maximum temperature in the Table. Use the
highest oil viscosity that is available in order to meet
Table 10
the required temperature during start-up.
Approximate Refill Capacity for the G3412C
Table 8 Engine Lubrication System
Engine Oil Viscosity Compartment or System Liters US Gal
Cat NGEO Ambient Temperature Engine crankcase 170 44.2
Grade of Standard oil pan
Viscosity Minimum Maximum

SAE 30(1) 0 °C (32 °F) 40 °C (104 °F)

SAE 40(1) 5 °C (41 °F) 50 °C (122 °F)
(1) Cat NGEO is available in these grades only. Multigrade oils
are NOT recommended for use in Caterpillar Gas Engines.
If other grades of viscosity are selected, ensure that the oil
meets the requirements for Caterpillar Gas Engines. Consult
the supplier of the oil.
For further information about oils, see Special
Publication, SEBU6400, “Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations”.
Fuel
Fuel Recommendations
Caterpillar gas engines will operate successfully on
a broad range of gaseous fuels. Pipeline natural
gas has been used for many years. Commercial
fuel gases are mixtures of gases. These fuels
consist primarily of hydrocarbons (combinations of
hydrogen and carbon) and some inert gases. The
compositions of these gas mixtures have extreme
variations. Fuels such as wellhead gas, bio-gas,
and manufactured gas need to be reviewed for
acceptability. Analyze the fuel in order to determine
the following characteristics:
SEBU6883-08 51
Maintenance Section
Refill Capacities

• Composition Coolant/antifreeze is normally composed of three

elements: water, glycol, and additives. Each element
• Contaminants must meet specific guidelines.

• Heat value Water

• Methane number Deionized water or distilled water is

recommended for use in engine cooling systems.
• Specific gravity If distilled water or deionized water is not available,
use water with the properties that are listed in Table
Field gas can have varying characteristics of 11.
combustion. Field gas can contain numerous
harmful impurities. The impurities can alter the BTU Table 11
content. The impurities can also alter the methane Caterpillar Minimum Acceptable Water Requirements
number. The impurities include everything from
water up to complex hydrocarbons that can lead to Property Maximum Limit ASTM Test
detonation and severe engine damage. To minimize 40 mg/L “D512”,
these effects, Caterpillar recommends the following Chloride (Cl)
(2.4 grains per US gal) “D4327”
guidelines:
100 mg/L
Sulfate (SO4) “D516”
(5.9 grains per US gal)
1. Evaluate the fuel with the Caterpillar Methane
Number Program, LEKQ6378. 170 mg/L
Total Hardness “D1126”
(10 grains per US gal)
Methane values below 30 are not recommended
340 mg/L
for use in a Caterpillar engine. Fuels with a Total Solids
(20 grains per US gal)
“D1888”
methane number that is below 30 must first be
processed in order to remove harmful impurities in Acidity pH of 5.5 to 9.0 “D1293”
the fuel and raising the methane number into the
acceptable range.
NOTICE
2. If necessary, use an engine that is configured Use of water that does not meet the recommendations
for a fuel that has a high energy. Consult the for the cooling system will damage the cooling system.
appropriate manual for the engine in order to
determine the recommended engine timing. Do not use these types of water in the cooling system:
sea water, softened water that has been conditioned
3. Reduce the oil change interval according to the with salt, hard water, and tap water.
results of the oil analysis.
Only use water that meets the recommendations for
For further information on fuels, see Special the cooling system.
Publication, SEBU6400, “Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations”. If you are not sure about the properties of your water,
consult one of the following sources for a water
Cooling System analysis:

Coolant Recommendations • Caterpillar dealer

During shipping and storage, the engine must be • Local water utility company
protected from damage that can be caused by
freezing of the cooling system. If the engine is • Agricultural agent
shipped to a site with freezing temperatures and/or
if the engine is stored in a location with freezing • Independent laboratory
temperatures, the cooling system must contain
antifreeze that will withstand the lowest ambient
temperature. Frequently check the concentration
of glycol in the coolant/antifreeze. Make sure that
the concentration is adequate in order to prevent
freezing. Otherwise, the cooling system must be
completely drained.
52 SEBU6883-08
Maintenance Section
Refill Capacities

Glycol Table 12
Recommended Coolant/Antifreeze and Service
NOTICE Life of the Coolant/Antifreeze
Do not use Extended Life Coolant (ELC) with Coolant/Antifreeze Service Life (1)
Caterpillar Gas Engines.
Cat NGEC
ELC was not formulated for use in Caterpillar Gas En- Three Years
Cat DEAC
gines.
Commercial Heavy-Duty
Use only the coolant/antifreeze that is recommended. Coolant/Antifreeze that Two Years
meets “ASTM D6210”

Preferred – Cat NGEC (Natural Gas Engine Commercial Heavy-Duty

Coolant)
Alternatively, use Cat DEAC (Diesel Engine
Antifreeze/Coolant) or a commercial heavy-duty
coolant/antifreeze that meets “ASTM D6210” or
“ASTM D4985” specifications.
NOTICE
Do not use a commercial coolant/antifreeze that only
meets the ASTM “D3306” specification. This type of
coolant/antifreeze is made for light duty automotive
applications.
Use only the coolant/antifreeze that is recommended.
Acceptable – In applications that do not require
protection from boiling or from freezing, a mixture of
Cat SCA and water that meets the properties that are
listed in Table 11 is acceptable.
Note: The preferred coolant/antifreeze and the
acceptable mixture of SCA and water require
different concentrations of SCA. Refer to the Special
Publication, SEBU6400, “Supplemental Coolant
Additive (SCA)” topic.
Table 12 is a list of the coolant/antifreeze that is
recommended for Caterpillar Gas Engines. The
service life of the coolant/antifreeze that is used in
Caterpillar Gas Engines is also listed. To achieve
this service life, the coolants must be properly
maintained. The maintenance program includes
S·O·S coolant analysis.
Coolant/Antifreeze that One Year
meets “ASTM D4985”
Cat SCA and Water Two Years
Commercial SCA and
Water
One Year
(1) The service life of coolant is also limited by use (service hours).
Refer to the specific engine’s Operation and Maintenance
Manual, “Maintenance Interval Schedule”.
Additives
Preferred – Cat Supplemental Coolant Additive
(SCA)
Acceptable – A commercial SCA that provides
1200 mg/L (70 grains per US gal) or 1200 ppm of
nitrites in the final mixture of coolant/antifreeze
Note: A 50/50 concentration of Cat NGEC or of
Cat DEAC does not require a treatment with
an SCA at the initial fill. Commercial heavy-duty
coolant/antifreeze that meets “ASTM D6210”
or “ASTM D4985” specifications may require a
treatment with an SCA at the initial fill. Read the label
or the instructions that are provided by the OEM of
the product.
To ensure that the correct amount of SCA is in the
cooling system, the concentration of SCA must be
tested on a scheduled basis. Obtain an S·O·S coolant
analysis (Level 1) or use a test kit to check the
concentration of the SCA according to this Operation
and Maintenance Manual, “Maintenance Interval
Schedule”.

For further information on coolant, see Special

Publication, SEBU6400, “Caterpillar Gas Engine
Lubricant, Fuel, and Coolant Recommendations”.
SEBU6883-08 53
Maintenance Section
Refill Capacities

Coolant Capacities
To properly maintain the cooling system, the Total
Cooling System capacity must be determined. The
Total Cooling System capacity will vary between
individual installations. The External System
capacity includes the following components: engine,
expansion tank, heat exchanger, radiator, and piping.
Refer to the specifications that are provided by
Caterpillar or by the OEM of the equipment. Record
the Total Cooling System capacity in the appropriate
Tables:

Table 13
Approximate Refill Capacities for the G3408C
Engine Cooling System
Compartment or System Liters US Gal
Engine only 55.5 14.5
External system(1)
Total cooling system(2)
(1) The external system includes a radiator and piping. Refer to
Caterpillar specifications or refer to the OEM specifications.
Enter the external system capacity in this row.
(2) Add the “engine only” capacity to the “external system”
capacity. Enter the total in this row.

Table 14
Approximate Refill Capacities for the G3412C
Engine Cooling System
Compartment or System Liters US Gal
Engine only 75 20
External system(1)
Total cooling system(2)
(1) The external system includes a radiator and piping. Refer to
Caterpillar specifications or refer to the OEM specifications.
Enter the external system capacity in this row.
(2) Add the “engine only” capacity to the “external system”
capacity. Enter the total in this row.
54
Maintenance Section
Maintenance Interval Schedule
i02752300
Maintenance Interval Schedule
(Standard)
SMCS Code: 1000; 4450; 7500
Ensure that all safety information, warnings,
and instructions are read and understood before
any operation or any maintenance procedures
are performed. The user is responsible for
the performance of maintenance, including all
adjustments, the use of proper lubricants, fluids,
filters, and the installation of new components
due to normal wear and aging. The performance
of this product may be diminished if proper
maintenance intervals and procedures are not
followed. Components may experience accelerated
wear if proper maintenance intervals and procedures
are not followed.
Use whichever of the following that occurs first in
order to determine the maintenance intervals: fuel
consumption, service hours, and calendar time .
Products that operate in severe operating conditions
may require more frequent maintenance.
Before each consecutive interval is performed, all
maintenance from the previous intervals must be
performed.
When Required
Batteries - Replace ............................................... 58
Engine Air Cleaner Element - Replace ................. 68
Overhaul Considerations ...................................... 86
Valve Stem Projection - Measure/Record ............. 92
Daily
Air Tank Moisture and Sediment - Drain ............... 57
Control Panel - Inspect ......................................... 60
Driven Equipment - Inspect/Replace/Lubricate ... 67
Engine Air Cleaner Service Indicator - Inspect ..... 70
Engine Air Precleaner - Clean .............................. 71
Engine Oil Level - Check ...................................... 72
Fuel System Fuel Filter Differential Pressure -
Check .................................................................. 77
Instrument Panel - Inspect .................................... 81
Power Take-Off Clutch - Check/Adjust/Lubricate .. 88
Walk-Around Inspection ........................................ 93
Every 250 Service Hours
Belts - Inspect/Adjust/Replace .............................. 59
Engine Oil Sample - Obtain .................................. 72
Every 750 Service Hours
Battery Electrolyte Level - Check .......................... 59
Belts - Inspect/Adjust/Replace .............................. 59
SEBU6883-08
Cooling System Coolant Sample (Level 1) -
Obtain ................................................................. 63
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add .................................................
Crankshaft Vibration Damper - Inspect .................
64
65
Engine - Clean ...................................................... 67
Engine Oil and Filter - Change ............................. 73
Engine Valve Lash - Inspect/Adjust ...................... 76
Engine Valve Rotators - Inspect ........................... 76
Exhaust Piping - Inspect ....................................... 77
Gas Pressure Regulator - Check .......................... 78
Hoses and Clamps - Inspect/Replace .................. 78
Ignition System Spark Plugs - Check/Adjust/
Replace ............................................................... 80
Ignition System Timing - Check/Adjust ................. 80
Radiator - Clean .................................................... 88
Initial 750 Service Hours
Valve Stem Projection - Measure/Record ............. 92
Every 1500 Service Hours
Actuator Control Linkage - Lubricate .................... 57
Carburetor Air/Fuel Ratio - Check/Adjust ............. 60
Crankcase Blowby - Measure/Record .................. 65
Cylinder Pressure - Measure/Record ................... 66
Engine Crankcase Breather - Clean ..................... 71
Engine Protective Devices - Check ...................... 75
Engine Speed/Timing Sensor - Clean/Inspect ...... 76
Speed Sensor - Clean/Inspect .............................. 89
Every 3000 Service Hours
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 63
Driven Equipment - Check .................................... 67
Ignition System Transformer Resistance - Test .... 81
Inlet Air System - Inspect ...................................... 81
Starting Motor - Inspect ........................................ 90
Water Pump - Inspect ........................................... 95
Every 3 Years
Batteries - Replace ............................................... 58
Exhaust Bypass - Inspect ..................................... 77
Every 4000 Service Hours
Alternator - Inspect ............................................... 57
Every 8000 Service Hours
Turbocharger - Inspect .......................................... 91
Between 9000 and 12 000 Service Hours
Overhaul (Top End) ............................................... 84
Between 18 000 and 24 000 Service Hours
Overhaul (Major) ................................................... 82
SEBU6883-08 55
Maintenance Section
Maintenance Interval Schedule

Every 24 000 Service Hours or 3 Years

Cooling System Coolant (DEAC) - Change .......... 61
56
Maintenance Section
Maintenance Interval Schedule
i02752313
Maintenance Interval Schedule
(Standby)
SMCS Code: 1000; 4450; 7500
Ensure that all safety information, warnings,
and instructions are read and understood before
any operation or any maintenance procedures
are performed. The user is responsible for
the performance of maintenance, including all
adjustments, the use of proper lubricants, fluids,
filters, and the installation of new components
due to normal wear and aging. The performance
of this product may be diminished if proper
maintenance intervals and procedures are not
followed. Components may experience accelerated
wear if proper maintenance intervals and procedures
are not followed.
Use whichever of the following that occurs first in
order to determine the maintenance intervals: fuel
consumption, service hours, and calendar time .
Products that operate in severe operating conditions
may require more frequent maintenance.
Before each consecutive interval is performed, all
maintenance from the previous intervals must be
performed.
Every Week
Air Tank Moisture and Sediment - Drain ............... 57
Automatic Start/Stop - Inspect .............................. 57
Battery Charger - Check ....................................... 58
Battery Electrolyte Level - Check .......................... 59
Control Panel - Inspect ......................................... 60
Engine Air Cleaner Service Indicator - Inspect ..... 70
Engine Air Precleaner - Clean .............................. 71
Engine Oil Level - Check ...................................... 72
Fuel System Fuel Filter Differential Pressure -
Check .................................................................. 77
Instrument Panel - Inspect .................................... 81
Jacket Water Heater - Check ................................ 82
Standby Generator Set Maintenance
Recommendations .............................................. 89
Walk-Around Inspection ........................................ 94
Every 250 Service Hours or 1 Year
Engine Oil and Filter - Change ............................. 73
Every Year
Actuator Control Linkage - Lubricate .................... 57
Alternator - Inspect ............................................... 57
Belts - Inspect/Adjust/Replace .............................. 59
Carburetor Air/Fuel Ratio - Check/Adjust ............. 60
Cooling System Coolant Sample (Level 1) -
Obtain ................................................................. 63
SEBU6883-08
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................. 63
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add .................................................
Crankcase Blowby - Measure/Record ..................
64
65
Crankshaft Vibration Damper - Inspect ................. 65
Cylinder Pressure - Measure/Record ................... 66
Engine - Clean ...................................................... 67
Engine Air Cleaner Element - Replace ................. 68
Engine Crankcase Breather - Clean ..................... 71
Engine Oil Sample - Obtain .................................. 72
Engine Performance - Test ................................... 75
Engine Protective Devices - Check ...................... 75
Engine Speed/Timing Sensor - Clean/Inspect ...... 76
Engine Valve Lash - Inspect/Adjust ...................... 76
Engine Valve Rotators - Inspect ........................... 76
Gas Pressure Regulator - Check .......................... 78
Hoses and Clamps - Inspect/Replace .................. 78
Ignition System Spark Plugs - Check/Adjust/
Replace ............................................................... 80
Ignition System Timing - Check/Adjust ................. 80
Inlet Air System - Inspect ...................................... 81
Radiator - Clean .................................................... 88
Speed Sensor - Clean/Inspect .............................. 89
Starting Motor - Inspect ........................................ 90
Turbocharger - Inspect .......................................... 91
Water Pump - Inspect ........................................... 95
Every 3 Years
Batteries - Replace ............................................... 58
Cooling System Coolant (DEAC) - Change .......... 61
Exhaust Bypass - Inspect ..................................... 77
Exhaust Piping - Inspect ....................................... 77
Governor - Inspect ................................................ 78
Hoses and Clamps - Replace ............................... 79
Ignition System Transformer Resistance - Test .... 81
Water Temperature Regulator - Replace .............. 95
SEBU6883-08 57
Maintenance Section
Actuator Control Linkage - Lubricate

i01600724 1. Open the drain valve that is on the bottom of the

air tank. Allow the moisture and sediment to drain.
Actuator Control Linkage -
Lubricate 2. Close the drain valve.

SMCS Code: 1265-086 i02084374

Alternator - Inspect
SMCS Code: 1405-040

Inspect the alternator for the following conditions:

• Proper connections
• Clean ports for cooling airflow
• Proper charging of the battery
Observe the ammeter during engine operation in
g00709892 order to ensure proper battery performance and/or
Illustration 40 proper performance of the electrical system.
Grease fittings
Make repairs, if necessary. See the Service Manual
Apply grease to the grease fittings. Use a hand for service procedures. Consult your Caterpillar
grease gun and lubricate the grease fittings with dealer for assistance.
MPGM.
i01039675
Check the Linkage
Automatic Start/Stop - Inspect
Check the linkage for proper operation. Adjust
the linkage, if necessary. Refer to the engine’s (Generator Set)
Specifications.
SMCS Code: 4462

i00351324 The generator set must be ready to operate under a

load at any time. After performing maintenance on
Air Tank Moisture and the generator set, inspect the position of the control
Sediment - Drain switches. Ensure the following conditions:

SMCS Code: 1466-543-M&S • The starting system is enabled.

Moisture and sediment in the air starting system can • The control switches are in the correct position for
cause the following conditions: automatic starting.

• Freezing • The switchgear and the automatic transfer switches

• Corrosion of internal parts
• Malfunction of the air starting system
that are associated with the generator are enabled.
For more information, see the Operation and
Maintenance Manual for the generator and the
control panel.

When opening the drain valve, wear protective

gloves, a protective face shield, protective cloth-
ing, and protective shoes. Pressurized air could
cause debris to be blown and result in personal
injury.
58
Maintenance Section
Batteries - Replace
i01041029
Batteries - Replace
SMCS Code: 1401-510
Batteries give off combustible gases which can
explode. A spark can cause the combustible gas-
es to ignite. This can result in severe personal in-
jury or death.
Ensure proper ventilation for batteries that are in
an enclosure. Follow the proper procedures in or-
der to help prevent electrical arcs and/or sparks
near batteries. Do not smoke when batteries are
serviced.
1. Turn the key start switch to the OFF position.
Remove the key and all electrical loads.
2. Turn OFF the battery charger. Disconnect the
charger.
3. The NEGATIVE “-” cable connects the NEGATIVE
“-” battery terminal to the ground plane. Disconnect
the cable from the NEGATIVE “-” battery terminal.
4. The POSITIVE “+” cable connects the POSITIVE
“+” battery terminal to the starting motor.
Disconnect the cable from the POSITIVE “+”
battery terminal.
Note: Always recycle a battery. Never discard a
battery. Return used batteries to an appropriate
recycling facility.
5. Remove the used battery.
6. Install the new battery.
Note: Before connecting the cables, ensure that the
key start switch is OFF.
7. Connect the cable from the starting motor to the
POSITIVE “+” battery terminal.
8. Connect the cable from the ground plane to the
NEGATIVE “-” battery terminal.
SEBU6883-08
i01039758
Battery Charger - Check
SMCS Code: 1401-535
Checking Before Start-Up
Check the battery charger for proper operation. If
the batteries are properly charged, the needle of the
ammeter will register near “0” (zero).
The battery charger must not produce excessive
current during start-up. Alternatively, the charger
must be automatically disconnected for start-up.
If the engine has an alternator, the charger must
be automatically disconnected during start-up and
during engine operation.
Charging the Battery
Never disconnect any charging unit circuit or bat-
tery circuit cable from the battery when the charg-
ing unit is operated. A spark can cause an explo-
sion from the flammable vapor mixture of hydro-
gen and oxygen that is released from the elec-
trolyte through the battery outlets. Injury to per-
sonnel can be the result.
Perform the following procedure to charge the
battery:
1. Ensure that the charger is turned OFF.
2. Adjust the voltage of the charger in order to match
the voltage of the battery.
3. Connect the POSITIVE “+” lead of the charger
to the POSITIVE “+” battery terminal. Connect
the NEGATIVE “-” lead of the charger to the
NEGATIVE “-” battery terminal.
4. Turn ON the battery charger.
Overcharging of Batteries
Overcharging reduces the service life of batteries.
Use a battery charger that will not overcharge the
battery. DO NOT charge the battery if the meter of
the battery charger is in the RED zone.
Overcharging is indicated by the following symptoms:
• The battery is very warm to the touch.
• A strong odor of acid is present.
• The battery emits smoke or a dense vapor (gas).
SEBU6883-08 59
Maintenance Section
Battery Electrolyte Level - Check

Perform one of the following procedures if the battery

shows symptoms of overcharging:
All lead-acid batteries contain sulfuric acid which
• Reduce the rate of charging by a significant can burn the skin and clothing. Always wear a face
amount. Complete the charging at the reduced
shield and protective clothing when working on or
rate.
near batteries.
• Turn OFF the charger.
1. Remove the filler caps. Maintain the electrolyte
Table 15 describes the effects of overcharging on level to the “FULL” mark on the battery.
different types of batteries.
If the addition of water is necessary, use distilled
Table 15 water. If distilled water is not available use clean
Effects of Overcharging Batteries water that is low in minerals. Do not use artificially
softened water.
Type of Battery Effect
2. Check the condition of the electrolyte with the
245-5829 Coolant Battery Tester Refractometer.
Caterpillar General Service All of the battery cells have
Batteries a low level of electrolyte.
Caterpillar Premium High 3. Keep the batteries clean.
Output Batteries
Clean the battery case with one of the following
cleaning solutions:

Caterpillar Maintenance
Free Batteries
Checking After Stopping
Ensure that the battery charger is connected
properly. Observe the meter of the charger. Record
the amperage.
When the plates of the
battery are inspected
through the filler holes, the
plates may appear to be
warped. This is caused by
an excessive temperature.
The battery may not pass
a load test.
The battery may not accept
a charging current.
The battery may not pass
a load test.
Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
i02601752
• A mixture of 0.1 kg (0.2 lb) of baking soda and
1 L (1 qt) of clean water
• A mixture of 0.1 L (0.11 qt) of ammonia and 1 L
(1 qt) of clean water
Thoroughly rinse the battery case with clean water.
Use a fine grade of sandpaper to clean the
terminals and the cable clamps. Clean the items
until the surfaces are bright or shiny. DO NOT
remove material excessively. Excessive removal
of material can cause the clamps to not fit properly.
Coat the clamps and the terminals with 5N-5561
Silicone Lubricant, petroleum jelly or MPGM.
i02667833

Battery Electrolyte Level - Inspection

Check Inspect the alternator belt and the fan drive belts for
wear and for cracking. Replace the belts if the belts
SMCS Code: 1401-535-FLV are not in good condition.

When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing.
Check the belt tension according to the information in
the Service Manual, “Specifications”.
Slippage of loose belts can reduce the efficiency
of the driven components. Vibration of loose belts
can cause unnecessary wear on the following
components:

• Belts
60 SEBU6883-08
Maintenance Section
Carburetor Air/Fuel Ratio - Check/Adjust

• Pulleys 3. Move the pulley in order to adjust the belt tension.

• Bearings 4. Tighten the adjusting nut to the proper torque.

If the belts are too tight, unnecessary stress is placed
on the components. This reduces the service life of
the components.
Adjusting the Alternator Belt
5. Tighten the mounting bolt to the proper torque.
For the proper torque specifications, refer to the
Service Manual, “Specifications” module.
Replacement
For applications that require multiple drive belts,
replace the drive belts in matched sets. Replacing
one drive belt of a matched set will cause the new
drive belt to carry more load because the older drive
belts are stretched. The additional load on the new
drive belt could cause the new drive belt to fail.

i01005891

Carburetor Air/Fuel Ratio -

Check/Adjust
SMCS Code: 1266-535; 1266

An engine failure may occur if the air/fuel ratio is

not appropriate for the fuel and for the operating
conditions. The service life of the turbocharger, of the
valves, and of the other components may be reduced.
g01092641
Illustration 41 Ensure that the carburetor is adjusted properly so
Typical alternator that the air/fuel ratio is correct.
(1) Mounting bolt
(2) Adjusting nuts For information on adjusting the carburetor, refer to
(3) Mounting bolt the Service Manual, “Systems Operation/Testing
and Adjusting”, or refer to the Special Instruction,
1. Remove the drive belt guard. “Installation and Initial Start-Up Procedure”.
2. Loosen mounting bolt (1), adjusting nuts (2) and
mounting bolt (3). i01762721

3. Turn adjusting nuts (2) in order to increase or Control Panel - Inspect

decrease the drive belt tension.
SMCS Code: 4490-040; 7451-040
4. Tighten adjusting nuts (2). Tighten mounting bolt
(3). Tighten mounting bolt (1). For the proper Inspect the condition of the panel. If a component is
torque, see the Service Manual, “Specifications” damaged, ensure that the component is repaired or
module. that the component is replaced. If equipped, ensure
that the electronic displays are operating properly.
5. Reinstall the drive belt guard.
Inspect the wiring for good condition. Ensure that the
If new drive belts are installed, check the drive belt wiring connections are secure.
tension again after 30 minutes of engine operation at
the rated rpm.

Adjusting the Fan Drive Belt

1. Loosen the mounting bolt for the pulley.

2. Loosen the adjusting nut for the pulley.

SEBU6883-08 61
Maintenance Section
Cooling System Coolant (DEAC) - Change

Record the Data and Review the

Data
If equipped, check the gauges and check the
indicators frequently during normal operation. Record
the data in a log. Compare the new data to the data
that was previously recorded. Comparing the new
data to the recorded data will establish the normal
gauge readings for the engine. A gauge reading that
is abnormal may indicate a problem with operation
or with the gauge.

i02057429

Cooling System Coolant

(DEAC) - Change
SMCS Code: 1350-044

Clean the cooling system before the recommended

g00719046
maintenance interval if the following conditions exist: Illustration 43
Drain plugs on the oil cooler, water pumps, and elbows
• The engine overheats frequently.
3. Open the cooling system drain valve. Remove the
• Foaming is observed. drain plugs.

• Oil has entered the cooling system and the coolant
is contaminated.
Drain the Cooling System
1. Stop the engine and allow the engine to cool.
Ensure that the engine will not start when the
cooling system is drained.
NOTICE
Dispose of used engine coolant properly or recycle.
Various methods have been proposed to reclaim used
coolant for reuse in engine cooling systems. The full
distillation procedure is the only method acceptable by
Caterpillar to reclaim the used coolant.
For information regarding the disposal and the
recycling of used coolant, consult your Caterpillar
dealer or consult Caterpillar Dealer Service Tools:

Outside Illinois: 1-800-542-TOOL

Inside Illinois: 1-800-541-TOOL
Canada: 1-800-523-TOOL

Clean the Cooling System

1. After the cooling system has been drained, flush
the cooling system with clean water in order to
remove any debris.

2. Close the cooling system drain valve. Clean the

g00781022
Illustration 42 drain plugs and install the plugs.

2. Loosen the cooling system filler cap slowly in

order to relieve any pressure. Remove the cooling
system filler cap.
NOTICE
Use of commercially available cooling system clean-
ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are ap-
proved for Caterpillar engines.
62
Maintenance Section
Cooling System Coolant (DEAC) - Change
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per 15 L
(4 US gal) of the cooling system capacity. Install
the cooling system filler cap.
4. Start the engine. Operate the engine for a
minimum of 30 minutes with a coolant temperature
of at least 82 °C (180 °F).
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the cooling system drain
valve. Remove the drain plugs.
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com-
ponents.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
cleaning agent are gone.
6. Allow the water to drain. Flush the cooling system
with clean water until the water that drains is
clean. Close the cooling system drain valve. Clean
the drain plugs and install the plugs.
Cleaning a Cooling System that
has Heavy Deposits or Plugging
Note: For the following procedure to be effective,
there must be an active flow through the cooling
system components.
1. After the cooling system has been drained, flush
the cooling system with clean water in order to
remove any debris.
2. Close the cooling system drain valve. Clean the
drain plugs and install the plugs.
NOTICE
Use of commercially available cooling system clean-
ers may cause damage to cooling system compo-
nents. Use only cooling system cleaners that are ap-
proved for Caterpillar engines.
SEBU6883-08
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
3. Fill the cooling system with a mixture of clean
water and Caterpillar Fast Acting Cooling System
Cleaner. Add 0.5 L (1 pint) of cleaner per
3.8 to 7.6 L (1 to 2 US gal) of the cooling system
capacity. Install the cooling system filler cap.
4. Start the engine. Operate the engine for a
minimum of 90 minutes with a coolant temperature
of at least 82 °C (180 °F).
5. Stop the engine and allow the engine to cool.
Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap. Open the cooling system drain
valve. Remove the drain plugs. Allow the water
to drain.
NOTICE
Improper or incomplete rinsing of the cooling system
can result in damage to copper and other metal com-
ponents.
To avoid damage to the cooling system, make sure
to completely flush the cooling system with clear wa-
ter. Continue to flush the system until all signs of the
cleaning agent are gone.
6. Flush the cooling system with clean water until
the water that drains is clean. Close the cooling
system drain valve. Clean the drain plugs and
install the plugs.
Fill the Cooling System
NOTICE
Fill the cooling system no faster than 19 L (5 US gal)
per minute to avoid air locks.
Note: For information about the proper coolant to use,
see this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” (Maintenance
Section). For the capacity of the cooling system,
see this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” (Maintenance
Section).
1. Fill the cooling system with coolant/antifreeze. Do
not install the cooling system filler cap.
2. Start the engine. Operate the engine in order to
purge the air from the cavities of the engine block.
Allow the coolant to warm and allow the coolant
level to stabilize. Stop the engine.
SEBU6883-08
3. Check the coolant level. Maintain the coolant to
the proper level on the sight gauge (if equipped).
If a sight gauge is not equipped, maintain the
coolant within 13 mm (0.5 inch) below the bottom
of the filler pipe.
4. Clean the cooling system filler cap. Inspect
the gaskets of the cooling system filler cap. If
the gaskets of the cooling system filler cap are
damaged, discard the old cooling system filler cap
and install a new cooling system filler cap. If the
gaskets of the cooling system filler cap are not
damaged, use a 9S-8140 Pressurizing Pump in
order to pressure test the cooling system filler cap.
The correct pressure is stamped on the face of
the cooling system filler cap. If the cooling system
filler cap does not maintain the correct pressure,
install a new cooling system filler cap.
5. Start the engine. Inspect the cooling system for
leaks and for proper operating temperature.
i02064894
Cooling System Coolant
Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
For conventional heavy-duty coolant/antifreeze,
check the concentration of supplemental coolant
additive (SCA) regularly. The concentration of SCA
can be checked with an S·O·S coolant analysis
(Level 1).
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order
to receive the full effect of S·O·S analysis, you
must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.
Use the following guidelines for proper sampling of
the coolant:
• Never collect samples from expansion bottles.
• Never collect samples from the drain for a system.
63
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
• Keep the unused sampling bottles stored in plastic
bags.
• Keep the lids on empty sampling bottles until you
are ready to collect the sample.
• Complete the information on the label for the
sampling bottle before you begin to take the
samples.
• Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
from any other location.
• In order to avoid contamination, immediately place
the sample in the tube that is provided for mailing.
Submit the sample for Level 1 analysis.
Note: Level 1 results may indicate a need for
Level 2 Analysis.
For additional information about coolant analysis,
see the Special Publication, SEBU6400, “Caterpillar
Gas Engine Lubricant, Fuel and Coolant
Recommendations” or consult your Caterpillar dealer.
i02168823
Cooling System Coolant
Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. Supplies
for collecting samples can be obtained from your
Caterpillar dealer.
Refer to this Operation and Maintenance Manual,
“Cooling System Coolant Sample (Level 1) - Obtain”
(Maintenance Section) for the guidelines for proper
sampling of the coolant.
Submit the sample for Level 2 analysis.
For additional information about coolant analysis,
see the Special Publication, SEBU6400, “Caterpillar
Gas Engine Lubricant, Fuel, and Coolant
Recommendations” or consult your Caterpillar dealer.
64 SEBU6883-08
Maintenance Section
Cooling System Supplemental Coolant Additive (SCA) - Test/Add

i02017557 6. Repeat 5 until the solution changes color from red

to light gray, green, or blue. Record the number of
Cooling System Supplemental drops of “NITRITE TEST SOLUTION A” that were
Coolant Additive (SCA) - required to cause the color change.

Test/Add 7. Use Table 16 to interpret the results.

SMCS Code: 1352-045; 1395-081 Table 16

Number of Concentration Maintenance
Drops of SCA Required
Less than 25 Less than the Add SCA.
Cooling system coolant additive contains alkali. recommended Retest the
To help prevent personal injury, avoid contact with concentration of coolant.
the skin and eyes. Do not drink cooling system SCA
coolant additive.
25 to 30 The None
recommended
Note: Caterpillar recommends an S·O·S coolant concentration of
analysis (Level 1). SCA
More than 30 More than the Remove the
Test the Concentration of the SCA recommended
concentration of
coolant.
Replace with
SCA water only
Coolant/Antifreeze and SCA Retest the
coolant.
NOTICE
Do not exceed the recommended six percent supple-
mental coolant additive concentration. Add the SCA, If Necessary

Test the concentration of the SCA with the 8T-5296

Coolant Conditioner Test Kit. Follow the instructions
that are provided in the kit.
Water and SCA
NOTICE
Do not exceed the recommended eight percent sup-
plemental coolant additive concentration.
Test the concentration of the SCA with the 8T-5296
Coolant Conditioner Test Kit. Use the instructions
that follow:
1. Fill the syringe to the “1.0 ml” mark with the
coolant.
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
1. Remove the cooling system filler cap slowly.
Note: Always dispose of fluids according to local
regulations.
2. If necessary, drain some coolant in order to allow
space for the addition of the SCA.

2. Dispense the 1.0 mL coolant sample from the

syringe into the empty mixing bottle.

3. Add tap water to the mixing bottle in order to bring

the level up to the “10 ml” mark. Place the cap on
the bottle and shake the bottle.

4. Add 2 to 3 drops of the “NITRITE INDICATOR

SOLUTION B” to the mixing bottle. Move the bottle
in a circular motion in order to mix the solution.

5. Add 1 drop of “NITRITE TEST SOLUTION A” to

the mixing bottle. Move the bottle in a circular
motion in order to mix the solution.
SEBU6883-08
NOTICE
Excessive supplemental coolant additive concentra-
tion can form deposits on the higher temperature sur-
faces of the cooling system, reducing the engine’s
heat transfer characteristics. Reduced heat transfer
could cause cracking of the cylinder head and other
high temperature components.
Excessive supplemental coolant additive concentra-
tion could also result in blockage of the heat exchang-
er, overheating, and/or accelerated wear of the water
pump seal.
Do not exceed the recommended amount of supple-
mental coolant additive concentration.
3. Add the proper amount of SCA. The concentration
of the SCA depends on the type of coolant that
is used. To determine the proper amount, see
this Operation and Maintenance Manual, “Refill
Capacities and Recommendations” topic.
4. Clean the cooling system filler cap. Install the
cooling system filler cap.
i01333307
Crankcase Blowby -
Measure/Record
SMCS Code: 1317
Note: For a new G3400 Engine, the typical range for
crankcase blowby is approximately 22 to 37 L/Bkw-hr
(0.6 to 1.0 cu ft/Bhp-hr).
Measure the crankcase blowby of new engines.
Record the data. Continue to periodically measure
the blowby. Comparing the recorded data to the new
data provides information about the condition of the
engine.
Note: Crankcase blowby is one of the three factors
that help to determine the major overhaul interval.
For more information, see this Operation and
Maintenance manual, “Overhaul (Major)” topic
(Maintenance Section).
After a new engine is used for a short time, the
blowby can decrease as the piston rings are seated.
The blowby will gradually increase as the following
components show wear:
• piston rings
• cylinder liners
65
Maintenance Section
Crankcase Blowby - Measure/Record
Note: A problem with the piston rings causes the
oil to deteriorate rapidly. Information regarding the
condition of the piston rings can be obtained from
the measurement of the blowby and the results of
oil analysis.
The blowby of a worn engine may exceed the blowby
of a new engine by two times or more.
A sudden increase in blowby could indicate a broken
piston ring. The following conditions are other
potential sources of blowby:
• Worn valve guides
• A turbocharger seal that leaks
A rebuilt engine can have a high blowby due to the
following factors:
• The piston rings are not seated properly.
• Worn parts such as valve guides were not replaced.
Excessive blowby may indicate the need for an
overhaul. By keeping a record of the results, a
gradual increase in the amount of the blowby will be
noted until the amount has become excessive.
To measure the blowby, use the 8T-2700 Blowby/Air
Flow Indicator. Refer to Special Instruction,
SEHS8712, “Using the 8T-2700 Blowby/Airflow
Indicator Group”. The instruction is provided with the
tool.
Keep a record of the results.
For more information, see the Service Manual,
“Systems Operation/Testing and Adjusting”. For
assistance, consult your Caterpillar dealer.
i01333457
Crankshaft Vibration Damper
- Inspect
SMCS Code: 1205-040
Damage to the crankshaft vibration damper or failure
of the crankshaft vibration damper can increase
torsional vibrations. This can result in damage to
the crankshaft and to other engine components. A
deteriorating damper can cause excessive gear train
noise at variable points in the speed range.
The damper is mounted to the crankshaft which is
located behind the belt guard on the front of the
engine.
66 SEBU6883-08
Maintenance Section
Cylinder Pressure - Measure/Record

Visconic Damper • Fully open the throttle plate.

The visconic damper has a weight that is located • Minimize the cranking time. This will enable a
inside a fluid filled case. The weight moves in the maximum consistent cranking speed for the check.
case in order to limit torsional vibration. Also, the battery power will be conserved.

Inspect the damper for evidence of fluid leaks. If
a fluid leak is found, determine the type of fluid.
The fluid in the damper is silicone. Silicone has
the following characteristics: transparent, viscous,
smooth, and adhesive.
If the fluid leak is oil, inspect the crankshaft seals for
leaks. If a leak is observed, replace the crankshaft
seals.
Inspect the damper and repair or replace the damper
for any of the following reasons:
• The damper is dented, cracked, or leaking.
• The paint on the damper is discolored from heat.
• The engine has had a failure because of a broken
crankshaft.
• Analysis of the oil has revealed that the front main
bearing is badly worn.
• There is a large amount of gear train wear that is
not caused by a lack of oil.
Refer to the Service Manual or consult your
Caterpillar dealer for information about damper
replacement.
i01519864
Cylinder Pressure -
Measure/Record
A loss of cylinder pressure or a change of pressure
in one or more cylinders may indicate the following
conditions. These conditions may indicate a problem
with lubrication:
• Excessive deposits
• Guttering of valves
• A broken valve
• A piston ring that sticks
• A broken piston ring
• Worn piston rings
• Worn cylinder liners
If the cylinder pressure has risen by one or more
compression ratios, the engine needs a top end
overhaul in order to remove deposits. Failure to
remove the deposits will increase the chance for
detonation. Severe guttering of the valves will occur.
To measure the cylinder pressure, use the 193-5859
Cylinder Pressure Gauge Gp. Follow the procedure
in the Special Instruction, NEHS0798 that is included
with the gauge group. Record the pressure for
each cylinder. Use the Operation and Maintenance
Manual, “Valve Data Sheet” (Reference Materials
Section).
Illustration 44 is a graph of typical cylinder pressures
for engines with different compression ratios.

SMCS Code: 1223-082-CC; 1223; 7450-082

Measure the cylinder pressure of new engines.

Record the data. Continue to periodically measure
the cylinder pressure. Comparing the recorded data
to the new data provides information about the
condition of the engine.

Note: Cylinder pressure is one of the three

factors that help to determine the major overhaul
interval. For more information, see this Operation
and Maintenance manual, “Overhaul (Major)”
(Maintenance Section).

Cylinder pressure can be measured during inspection

of the spark plugs. Use the following guidelines for
checking the cylinder pressure:

• Remove all of the spark plugs.

SEBU6883-08 67
Maintenance Section
Driven Equipment - Check

i00935098

Driven Equipment -
Inspect/Replace/Lubricate
SMCS Code: 3279-040

Observe the driven equipment during operation. Look

for the following items:

• Unusual noise and vibration

• Loose connections
• Damaged parts
Perform any maintenance that is recommended
by the OEM of the driven equipment. Refer to the
literature of the OEM of the driven equipment for the
following service instructions.

• Inspection
• Lubricating grease and lubricating oil requirements
• Specifications for adjustment

Illustration 44
g00760309 • Replacement of components
(Y) Cylinder pressure in kPa (psi)
(X) Compression ratio
• Requirements for ventilation
(1) Normal range for cylinder pressure
i01664717

i00449093
Engine - Clean
Driven Equipment - Check SMCS Code: 1000-070
SMCS Code: 3279-535

To minimize bearing problems and vibration of the

engine crankshaft and the driven equipment, the
alignment between the engine and driven equipment
must be maintained properly.
Check the alignment according to the instructions
that are provided by the following manufacturers:
• Caterpillar
• OEM of the coupling
• OEM of the driven equipment
Personal injury or death can result from high volt-
age.
Moisture could create paths of electrical conduc-
tivity.
Make sure the unit is off line (disconnected from
utility and/or other generators), locked out and
tagged "Do Not Operate".
NOTICE
Water or condensation can cause damage to gen-
erator components. Protect all electrical components
from exposure to water.
68 SEBU6883-08
Maintenance Section
Engine Air Cleaner Element - Replace

• Operating conditions (dust, dirt and debris) may

NOTICE
Accumulated grease and oil on an engine is a fire haz-
ard. Keep the engine clean. Remove debris and fluid
spills whenever a significant quantity accumulates on
the engine.
Steam cleaning the engine will remove accumulated
oil and grease. A clean engine provides the following
benefits:
require more frequent service of the air cleaner
element.
• The air cleaner element may be cleaned up to
six times if the element is properly cleaned and
inspected.
• The air cleaner element should be replaced at least
one time per year. This replacement should be
performed regardless of the number of cleanings.

• Easy detection of fluid leaks
• Maximum heat transfer characteristics
• Ease of maintenance
Note: For more information on cleaning and drying
electric generators, refer to Special Instruction,
SEHS9124, “Cleaning and Drying of Electric Set
Generators”.
Replace the dirty paper elements with clean
elements. Before installation, thoroughly inspect the
element for tears and/or holes in the filter material.
Inspect the gasket or the seal of the element for
damage. Maintain a supply of suitable elements for
replacement purposes.

i01749609

Engine Air Cleaner Element -

Replace
SMCS Code: 1051-510; 1054-510

NOTICE
Never run the engine without an air cleaner element
g00317608
installed. Never run the engine with a damaged air Illustration 45
cleaner element. Do not use air cleaner elements with Fasteners for the air cleaner cover
damaged pleats, gaskets or seals. Dirt entering the
engine causes premature wear and damage to engine
components. Air cleaner elements help to prevent air-
borne debris from entering the air inlet.

NOTICE
Never service the air cleaner element with the engine
running since this will allow dirt to enter the engine.

Servicing the Air Cleaner Elements

If the air cleaner element becomes plugged, the air
pressure can split the filter material of the element.
g00781084
Unfiltered air will drastically accelerate internal Illustration 46
engine wear. Your Caterpillar dealer has the proper (1) Cover
air cleaner elements for your application. (2) Element
(3) Air inlet
The air cleaner may be mounted high above the
engine. If necessary, use a ladder or a platform to 1. Release the fasteners for cover (1).
reach the air cleaner.
2. Remove the cover and element (2).
• Check the precleaner (if equipped) daily for
accumulation of dirt and debris. Remove any dirt 3. Cover air inlet (3) with tape in order to keep dirt
and debris, as needed. out.
SEBU6883-08
4. Clean the inside of the cover and the body with
a clean, dry cloth.
5. Remove the tape for the air inlet. Install a new
element or a clean element.
6. Install the cover.
7. If necessary, reset the air cleaner service indicator.
Cleaning the Primary Air Cleaner
Elements
The primary air cleaner element can be used up
to six times if the element is properly cleaned and
inspected. When the element is cleaned, check the
filter material for rips or tears. Replace the element
at least one time per year regardless of the number
of cleanings.
Use clean elements while dirty elements are being
cleaned.
NOTICE
Do not clean the air cleaner elements by bumping or
tapping. This could damage the seals. Do not use el-
ements with damaged pleats, gaskets or seals. Dam-
aged elements will allow dirt to pass through. Engine
damage could result.
Visually inspect the elements before cleaning. Inspect
the elements for damage to the seal, the gaskets,
and the outer cover. Discard any damaged elements.
Air cleaner elements can be cleaned with pressurized
air and with a vacuum.
Pressurized Air
Pressurized air can be used to clean elements
that have not been cleaned more than two times.
Pressurized air will not remove deposits of carbon
and oil. Use filtered, dry air with a maximum pressure
of 207 kPa (30 psi).
g00281692
Illustration 47
69
Maintenance Section
Engine Air Cleaner Element - Replace
Note: When the elements are cleaned, always begin
with the clean side (inside) in order to force dirt
particles toward the dirty side (outside).
Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream
of air directly at the primary air cleaner element. Dirt
could be forced into the pleats.
Note: Refer to “Inspecting the Primary Air Cleaner
Elements”.
Vacuum Cleaning
Vacuum cleaning is a good method for cleaning
elements which require daily cleaning because of a
dry, dusty environment. Cleaning with pressurized air
is recommended prior to vacuum cleaning. Vacuum
cleaning will not remove deposits of carbon and oil.
Note: Refer to “Inspecting the Primary Air Cleaner
Elements”.
Inspecting the Primary Air Cleaner
Elements
g00281693
Illustration 48
Inspect the clean, dry element. Use a 60 watt blue
light in a dark room or in a similar facility. Place
the blue light in the element. Rotate the element.
Inspect the element for tears and/or holes. Inspect
the element for light that may show through the filter
material. If it is necessary in order to confirm the
result, compare the element to a new element that
has the same part number.
Do not use an element that has any tears and/or
holes in the filter material. Do not use an element with
damaged pleats, gaskets or seals. Discard damaged
elements.
Storing Primary Air Cleaner Elements
If an element that passes inspection will not be used
immediately, store the element for future use.
70
Maintenance Section
Engine Air Cleaner Service Indicator - Inspect
g00281694
Illustration 49
Do not use paint, a waterproof cover, or plastic as a
protective covering for storage. Restricted air flow
may result. To protect against dirt and damage, wrap
the elements in Volatile Corrosion Inhibited (VCI)
paper.
Place the element into a cardboard box for storage.
For identification, mark the outside of the container
and mark the element. Include the following
information:
• Date of cleaning
• Number of cleanings
Store the container in a dry location.
For more detailed information on cleaning the primary
air cleaner element, refer to Special Publication,
SEBF8062, “Procedure to Inspect and Clean Air
Filters”.
i01505252
Engine Air Cleaner Service
Indicator - Inspect
SMCS Code: 7452-040
A service indicator may be mounted on the air
cleaner element or in a remote location.
SEBU6883-08
g00517797
Illustration 50
Service indicator
Some engines may be equipped with a different
service indicator.
Observe the service indicator. Clean the air cleaner
element or replace the element when the following
conditions occur:
• The yellow diaphragm enters the red zone.
• The red piston locks in the visible position.
• The air restriction reaches 3.7 kPa
(15 inches of H2O).
Inspect the service indicator daily for cracks, holes, or
loose fittings. If any of these conditions are present,
repair the service indicator or replace the service
indicator.
Test the Service Indicator
Service indicators are important instruments.
• Check for ease of resetting. The service indicator
should reset in less than three pushes.
• Check the movement of the yellow core when the
engine is accelerated to the engine rated rpm.
The yellow core should latch approximately at the
greatest vacuum that is attained.
If the service indicator does not reset easily, or if the
yellow core does not latch at the greatest vacuum,
replace the service indicator. If the new service
indicator will not reset, the fitting for the service
indicator may be plugged.
SEBU6883-08 71
Maintenance Section
Engine Air Precleaner - Clean

Remove wing nut (1) and cover (2). Check for an

accumulation of dirt and debris in body (3). Clean the
body, if necessary.

After cleaning the precleaner, install cover (2) and

wing nut (1).

Note: When the engine is operated in dusty

applications, more frequent cleaning is required.

i01505354

Engine Crankcase Breather -

g00351792
Clean
Illustration 51
Porous filter SMCS Code: 1317-070

A porous filter is part of a fitting that is used for

mounting of the service indicator. Inspect the filter
for cleanliness. Clean the filter, if necessary. Use
compressed air or a clean, nonflammable solvent.

The service indicator may need to be replaced

frequently in environments that are severely dusty.
Replace the service indicator annually regardless
of the operating conditions. Replace the service
indicator when the engine is overhauled, and
whenever major engine components are replaced.

Note: When a new service indicator is installed,

excessive force may crack the top of the service g00781173
indicator. Tighten the service indicator to a torque Illustration 53
of 2 N·m (18 lb in). (1) Hose clamp
(2) Breather assembly
(3) Retaining clamp
i01397717
1. Loosen hose clamp (1). Slide the hose from
Engine Air Precleaner - Clean breather assembly (2).
SMCS Code: 1055-070 2. Loosen retaining clamp (3). Remove breather
assembly (2). Remove the crankcase breather’s
seal.

3. Wash the breather assembly in clean,

nonflammable solvent. Allow the breather
assembly to dry.

4. Inspect the seal for cracks or damage. If

necessary, replace the seal . Install the seal.

Note: Coat the rubber parts with clean engine oil or

petroleum jelly in order to make installation easier.

5. Install the breather assembly and the hose.

g00736588
Illustration 52
6. Tighten retaining clamp (3) to the torque that
Typical precleaner is recommended in the engine’s Specifications
(1) Wing nut module. Tighten hose clamp (1) according
(2) Cover to this Operation and Maintenance Manual,
(3) Body
“Specificatons” topic.
72 SEBU6883-08
Maintenance Section
Engine Oil Level - Check

i02070400 The oil level should be between “ADD” mark

Engine Oil Level - Check
SMCS Code: 1348-535-FLV
The most accurate check of the oil level is
performed when the engine is stopped. Perform this
maintenance on a surface that is as level as possible.
Note: For engines with positive crankcase ventilation,
remove the oil filler cap. Allow the crankcase pressure
to stabilize before checking the engine oil level.
(5) and “FULL” mark (6).
NOTICE
Engine damage can occur if the crankcase is filled
above the “FULL” mark on the oil level gauge (dip-
stick).
An overfull crankcase can enable the crankshaft to
dip into the oil. This will reduce the power that is de-
veloped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re-
duction of the oil’s ability to lubricate, reduction of oil
pressure, inadequate cooling of the pistons, oil blow-
ing out of the crankcase breathers, and excessive oil
consumption.

Excessive oil consumption will enable deposits to form

on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner.

If the oil level is above the “FULL” mark on the oil level
gauge, drain some of the oil immediately.

g00781190 2. If necessary, remove oil filler cap (2) and add

Illustration 54
oil. For the correct oil to use, see this Operation
(1) Oil level gauge (dipstick) and Maintenance Manual, “Refill Capacities and
(2) Oil filler cap
Recommendations” topic (Maintenance Section).
Do not fill the crankcase above “FULL” mark (6).
Clean the oil filler cap. Install the oil filler cap.

3. Record the amount of oil that is added. For the

next oil sample and analysis, include the total
amount of oil that has been added since the
previous oil change. This will help to provide the
most accurate oil analysis.

i01363663

Engine Oil Sample - Obtain

SMCS Code: 1348-554-SM
g00735162
Illustration 55
(3) “ENGINE STOPPED WITH OIL COLD” side In addition to a good preventive maintenance
(4) “ENGINE AT LOW IDLE WITH OIL WARM” side program, Caterpillar recommends using S·O·S oil
(5) “ADD” mark analysis at regularly scheduled intervals in order
(6) “FULL” mark to monitor the condition of the engine and the
maintenance requirements of the engine.
1. Ensure that oil level gauge (1) is seated.

a. If the engine is stopped, remove oil level Obtain the Sample and the Analysis
gauge (1). Observe the oil level on “ENGINE
STOPPED” side (3).

b. If the engine is operating, reduce the engine Hot oil and hot components can cause personal
speed to low idle. Remove oil level gauge (1) injury. Do not allow hot oil or hot components to
and observe the oil level on “LOW IDLE” side contact the skin.
(4).
SEBU6883-08 73
Maintenance Section
Engine Oil and Filter - Change

Before taking the sample, complete the Label, i02527724

PEEP5031 for identification of the sample. To help
obtain the most accurate analysis, provide the Engine Oil and Filter - Change
following information:
SMCS Code: 1318-510
• Engine model
• Service hours on the engine
Hot oil and hot components can cause personal
• The oil’s hours of use injury. Do not allow hot oil or hot components to
contact the skin.
• The amount of oil that has been added since the
last oil change
NOTICE
To ensure that the sample is representative of the Ensure that the engine is stopped before performing
oil in the crankcase, obtain a warm, well mixed oil this procedure. Attach a DO NOT OPERATE tag to the
sample. starting controls.

To avoid contamination of the oil samples, the tools

Do not drain the oil when the engine is cold. As the oil
and the supplies that are used for obtaining oil
cools, suspended waste particles settle on the bottom
samples must be clean.
of the oil pan. The waste particles are not removed
when the cold oil is drained. Drain the crankcase with
Caterpillar recommends using the sampling valve
the oil warm, immediately after the engine is stopped.
in order to obtain oil samples. The quality and
This method of draining allows the waste particles
the consistency of the samples is better when the
that are suspended in the oil to be drained.
sampling valve is used. The location of the sampling
valve allows oil that is flowing under pressure to be
Failure to follow this recommended procedure will
obtained during normal engine operation.
cause the waste particles to be recirculated through
the engine lubrication system with the new oil.
The 8T-9190 Fluid Sampling Bottle Group is
recommended for use with the sampling valve. The
bottle group includes the parts that are needed for
obtaining oil samples. Instructions are also provided.

NOTICE
Do not use the same vacuum sampling pump for ex-
tracting oil samples that is used for extracting coolant
samples.

A small residue of either type sample may remain in

the pump and may cause a false positive analysis for
the sample being taken.

Always use a designated pump for oil sampling and a

g00781251
designated pump for coolant sampling. Illustration 56
(1) Oil filler cap
Failure to do so may cause a false analysis which (2) Oil filter
could lead to customer and dealer concerns. (3) Oil level gauge (dipstick)
(4) Oil drain

If the engine is not equipped with a sampling valve,

use the 1U-5718 Vacuum Pump. The pump is Drain the Engine Oil
designed to accept sampling bottles. Disposable
tubing must be attached to the pump for insertion 1. After the engine has been operated at normal
into the sump. operating temperature, STOP the engine.

For instructions, see Special Publication, PEHP6001,

“How To Take A Good Oil Sample”. Consult your
Caterpillar dealer for complete information and
assistance in establishing an S·O·S program for your
engine.
74 SEBU6883-08
Maintenance Section
Engine Oil and Filter - Change

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and g00103713

Illustration 57
mandates.
Typical filter mounting base and filter gasket

2. Drain the oil.
a. If the engine has an oil drain valve, open the
valve in order to drain the oil. After the oil has
drained, close the valve.
b. If the engine does not have a drain valve,
remove an oil drain plug. Allow the oil to drain.
Replace the Oil Filter
1. Remove the oil filter with a 1U-8760 Chain
Wrench.
3. Clean the sealing surface of the filter mounting
base. Ensure that all of the old oil filter gasket is
removed.
NOTICE
Caterpillar oil filters are built to Caterpillar speci-
fications. Use of an oil filter not recommended by
Caterpillar could result in severe engine damage to
the engine bearings, crankshaft, etc., as a result of
the larger waste particles from unfiltered oil entering
the engine lubricating system. Only use oil filters
recommended by Caterpillar.

2. Cut the oil filter open with a 4C-5084 Oil Filter
Cutter. Break apart the pleats and inspect the oil
filter for metal debris.
An excessive amount of metal debris in the oil
filter may indicate early wear or a pending failure.
Use a magnet to differentiate between the ferrous
metals and the nonferrous metals that are found in
the oil filter element. Ferrous metals may indicate
wear on the steel and cast iron parts of the engine.
Nonferrous metals may indicate wear on the
aluminum parts, brass parts or bronze parts of
the engine. Parts that may be affected include
the following items: main bearings, rod bearings,
turbocharger bearings, and cylinder heads.
4. Apply clean engine oil to the new oil filter gasket.
NOTICE
Do not fill the oil filters with oil before installing them.
This oil would not be filtered and could be contaminat-
ed. Contaminated oil can cause accelerated wear to
engine components.
5. Install the oil filter. Tighten the oil filter until the
oil filter gasket contacts the base. Tighten the oil
filter by hand according to the instructions that are
shown on the oil filter. Do not overtighten the oil
filter.

Aluminum debris may indicate problems with the

bearings of the front gears. If you find aluminum
debris, inspect the vibration damper and the idler
gear bearings.

Due to normal wear and friction, it is not

uncommon to find small amounts of debris in the
oil filter element. If an excessive amount of debris
is found in the oil filter element, consult your
Caterpillar dealer in order to arrange for further
oil analysis.
SEBU6883-08
Fill the Engine Crankcase
NOTICE
Engine damage can occur if the crankcase is filled
above the “FULL” mark on the oil level gauge (dip-
stick).
An overfull crankcase can cause the crankshaft to dip
into the oil. This will reduce the power that is devel-
oped and also force air bubbles into the oil. These
bubbles (foam) can cause the following problems: re-
duction of the oil’s ability to lubricate, reduction of oil
pressure, inadequate cooling, oil blowing out of the
crankcase breathers, and excessive oil consumption.
Excessive oil consumption will cause deposits to form
on the pistons and in the combustion chamber. De-
posits in the combustion chamber lead to the following
problems: guttering of the valves, packing of carbon
under the piston rings, and wear of the cylinder liner.
If the oil level is above the “FULL” mark on the oil level
gauge, drain some of the oil immediately.
1. Remove the oil filler cap. Fill the crankcase with
the proper amount of oil. Refer to the Operation
and Maintenance Manual, “Refill Capacities &
Recommendations” topic (Maintenance Section).
NOTICE
To prevent crankshaft damage or bearing damage,
crank the engine with the fuel supply line closed. This
will ensure that all of the oil filters are filled with oil be-
fore the engine is started. Do not crank the engine for
more than 30 seconds. Allow the starting motor to cool
for two minutes before cranking again.
2. Close the fuel supply line. Crank the engine until
normal oil pressure shows on the oil pressure
gauge. Open the fuel supply line.
3. Start the engine according to this Operating
and Maintenance Manual, “Starting the Engine”
procedure (Operation Section). Operate the
engine at low idle rpm for two minutes.
This will ensure that the lubrication system has oil
and that the oil filters are filled. Inspect the engine
for oil leaks.
4. Stop the engine and allow the oil to drain back to
the sump for a minimum of ten minutes.
5. Remove the oil level gauge and check the oil
level. Maintain the oil level between the “ADD”
and “FULL” marks on the “ENGINE STOPPED”
side of the oil level gauge.
75
Maintenance Section
Engine Performance - Test
i01042067
Engine Performance - Test
SMCS Code: 1000-081
Operate the engine for a minimum of two hours at a
minimum load of 60 percent.
• Monitor the operation of the generator set.
• Observe the gauges. Ensure that the gauges are
in the normal ranges.
• Record the data. Maintain a record of the data for
the engine performance.
i00626013
Engine Protective Devices -
Check
SMCS Code: 7400-535
Alarms and shutoffs must function properly. Alarms
provide timely warning to the operator. Shutoffs help
to prevent damage to the engine. It is impossible
to determine if the engine protective devices are
in good working order during normal operation.
Malfunctions must be simulated in order to test the
engine protective devices.
A calibration check of the engine protective devices
will ensure that the alarms and shutoffs activate
at the setpoints. Ensure that the engine protective
devices are functioning properly.
NOTICE
During testing, abnormal operating conditions must be
simulated.
The tests must be performed correctly in order to pre-
vent possible damage to the engine.
To prevent damage to the engine, only authorized
service personnel or your Caterpillar dealer should
perform the tests.
Visual Inspection
Visually check the condition of all gauges, sensors
and wiring. Look for wiring and components that
are loose, broken, or damaged. Damaged wiring
or components should be repaired or replaced
immediately.
76 SEBU6883-08
Maintenance Section
Engine Speed/Timing Sensor - Clean/Inspect

i02799088
NOTICE
Engine Speed/Timing Sensor - Only qualified service personnel should perform this
Clean/Inspect maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
SMCS Code: 1905-040; 1905-070; 1907-040; ment procedure.
1907-070
Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life.

Ensure that the engine can not be started while

this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
to turn the flywheel.

Hot engine components can cause burns. Allow

additional time for the engine to cool before mea-
suring/adjusting valve lash clearance.

Ensure that the engine is stopped before measuring

g01398834
Illustration 58
1. Remove the sensor from the cover. Check the
condition of the end of the magnet. Check for
signs of wear and contaminants.
the valve lash. To obtain an accurate measurement,
allow the valves to cool before this maintenance is
performed.
Refer to the engine’s Specification manual for more
the valve lash settings, or the engine’s Systems
Operation/Testing and Adjusting manual for the
settings and the procedure.

2. Clean the metal shavings and other debris from

the face of the magnet. i01765711

3. Install the sensor and adjust the sensor according

Engine Valve Rotators - Inspect
to the engine’s Specifications.
SMCS Code: 1109-040

i02526257 NOTICE
A valve rotator which does not operate properly will
Engine Valve Lash - accelerate valve face wear and valve seat wear and
Inspect/Adjust shorten valve life. If a damaged rotator is not replaced,
valve face guttering could result and cause pieces of
SMCS Code: 1102-025 the valve to fall into the cylinder. This can cause piston
and cylinder head damage.
This maintenance is recommended by Caterpillar
as part of a lubrication and preventive maintenance Note: Use of a platform may be necessary to reach
schedule in order to help provide maximum engine the engine valve rotators.
life.
Perform this procedure after the valve lash has been
set.

1. Mark the tops of the valve rotators with a

permanent marker. Note the position of the marks.

2. Install the valve covers. See the Service Manual

for the procedure.
SEBU6883-08 77
Maintenance Section
Exhaust Bypass - Inspect

3. Start the engine. Operate the engine for 5 minutes. i00721010

Stop the engine.
Exhaust Piping - Inspect
4. Remove the valve covers. Observe the position of
the marks that are on the valve rotators. SMCS Code: 1061-040

If a valve fails to rotate, consult your Caterpillar

dealer.
Hot engine components can cause injury from
burns. Before performing maintenance on the
i01505507
engine, allow the engine and the components to
Exhaust Bypass - Inspect cool.

SMCS Code: 1057-040 Inspect the components of the exhaust system.

For instructions on removal and installation, see the
Service Manual, “Disassembly and Assembly”.
1. Remove the exhaust bypass valve.
The exhaust bypass valve cover is under spring
compression. To prevent personal injury, use cau-
tion when removing the cover.
2. Disassemble the valve.
Repair the components or replace the components if
any of the following conditions occur:
• Damage
• Cracks
• Leaks
• Loose connections
Consult your Caterpillar dealer for assistance.
Water Cooled Exhaust Manifolds
The water cooled exhaust manifolds do not require
maintenance unless excessive deposits build up in
the exhaust passages. Buildup of deposits cause
an increase in back pressure that will cause the
following conditions:

• Increased fuel consumption

• Reduced boost pressure
If excessive deposits build up in the exhaust
passages, clean the passages in order to remove
the deposits.
g00781274
Illustration 59
Exhaust bypass valve
i01505536
(1) Diaphragm
(2) Valve stem Fuel System Fuel Filter
(3) Breather
Differential Pressure - Check
3. Inspect diaphragm (1). If the diaphragm is worn or
cracked, replace the diaphragm. SMCS Code: 1261-535

4. Inspect valve stem (2) and the valve guide. If the A fuel filter differential pressure gauge must be
parts are excessively worn, replace the parts. installed in order to determine when the fuel filter
requires service. This gauge and the fuel filter are
5. Clean breather (3). supplied by the customer.

6. Assemble the valve.

7. Install the valve.

78
Maintenance Section
Gas Pressure Regulator - Check
A fuel filter differential pressure gauge indicates the
difference in fuel pressure between the inlet side
and the outlet side of the fuel filter. The differential
pressure increases as the fuel filter becomes
plugged.
Operate the engine at the rated speed and at the
normal operating temperature. Check the fuel filter
differential pressure. Service of the fuel filter depends
on the pressure of the fuel system:
• For low pressure gas fuel systems, service the
fuel filter when the fuel filter differential pressure
reaches 1.7 kPa (0.25 psi).
• For high pressure gas fuel systems, service the
fuel filter when the fuel filter differential pressure
reaches 34 kPa (5 psi).
For instructions, see Special Instruction, SEHS9298,
“Installation and Maintenance of Gaseous Fuel
Filters”. Consult your Caterpillar dealer for assistance.
i01348680
Gas Pressure Regulator -
Check
SMCS Code: 1270-535
Check the fuel pressure before the gas pressure
regulator and after the gas pressure regulator. Table
17 lists the fuel pressure that is required for the gas
pressure regulator.
Table 17
Requirements for Fuel Pressure To the Gas
Pressure Regulator
Fuel System Pressure
Low pressure gas 10.3 to 34 ± 2 kPa
(1.50 to 5 ± 0.25 psi)
Pressure of the Fuel Supply To the
Carburetor
The gas pressure regulator maintains a pressure
differential between the air and the fuel that is
supplied to the carburetor. After setting, the gas
pressure regulator will maintain the pressure
differential in response to changes in the air pressure.
SEBU6883-08
Use a water manometer for measuring the pressure
differential. Obtain the measurement when the
engine is operating at high idle rpm. After a load
is applied, the fuel pressure will usually decrease
by approximately 0.1 to 0.25 kPa (0.50 to 1 inches
of H2O). If the performance of the gas pressure
regulator is erratic, the gas pressure regulator may
require service.
Natural Gas
Set the pressure of the fuel supply to a maximum of
1 to 1.2 kPa (4 to 4.5 inches of H2O) HIGHER than
the ambient air pressure.
i01041704
Governor - Inspect
SMCS Code: 1264-040
Inspect the governor for oil leaks.
For service information, see the literature that is
provided by the OEM of the governor.
i02121526
Hoses and Clamps -
Inspect/Replace
SMCS Code: 7554-040; 7554-510
Inspect all hoses for leaks that are caused by the
following conditions:
• Cracking
• Softness
• Loose clamps
Replace hoses that are cracked or soft. Tighten any
loose clamps.
NOTICE
Do not bend or strike high pressure lines. Do not in-
stall bent or damaged lines, tubes or hoses. Repair
any loose or damaged fuel and oil lines, tubes and
hoses. Leaks can cause fires. Inspect all lines, tubes
and hoses carefully. Tighten all connections to the rec-
ommended torque.
Check for the following conditions:
• End fittings that are damaged or leaking
• Outer covering that is chafed or cut
SEBU6883-08
• Exposed wire that is used for reinforcement
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering
A constant torque hose clamp can be used in place
of any standard hose clamp. Ensure that the constant
torque hose clamp is the same size as the standard
clamp.
Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen.
This can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.
Each installation application can be different. The
differences depend on the following factors:
• Type of hose
• Type of fitting material
• Anticipated expansion and contraction of the hose
• Anticipated expansion and contraction of the
fittings
Replace the Hoses and the Clamps
Pressurized System: Hot coolant can cause seri-
ous burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pres-
sure.
1. Stop the engine. Allow the engine to cool.
2. Loosen the cooling system filler cap slowly in
order to relieve any pressure. Remove the cooling
system filler cap.
Note: Drain the coolant into a suitable, clean
container. The coolant can be reused.
3. Drain the coolant from the cooling system to a
level that is below the hose that is being replaced.
4. Remove the hose clamps.
5. Disconnect the old hose.
6. Replace the old hose with a new hose.
7. Install the hose clamps with a torque wrench.
79
Maintenance Section
Hoses and Clamps - Replace
Note: Refer to the Specifications, SENR3130,
“Torque Specifications” in order to locate the proper
torques.
8. Refill the cooling system.
9. Clean the cooling system filler cap. Inspect the
cooling system filler cap’s gaskets. Replace
the cooling system filler cap if the gaskets are
damaged. Install the cooling system filler cap.
10. Start the engine. Inspect the cooling system for
leaks.
i02164888
Hoses and Clamps - Replace
SMCS Code: 1380-510
Note: For instructions on draining the cooling system
and filling the cooling system, see this Operation
and Maintenance Manual, “Cooling System Coolant
(DEAC) - Change” topic or see the Operation and
Maintenance Manual, “Cooling System Coolant
(ELC) - Change” topic (Maintenance Section).
1. Drain the cooling system.
2. Remove the used hoses and clamps. Discard the
items.
3. Install new hoses and clamps. For the
correct torque to use on the hose clamps,
see the Specifications, SENR3130, “Torque
Specifications”, “Hose Clamps” topic.
4. Fill the cooling system.
5. Start the engine. Inspect the hose connections for
leaks.
80
Maintenance Section
Ignition System Spark Plugs - Check/Adjust/Replace
i01342582
Ignition System Spark Plugs -
Check/Adjust/Replace
SMCS Code: 1555-535
Ignition systems can cause electrical shocks.
Avoid contacting the ignition system components
and wiring.
Do not attempt to remove the valve covers when
the engine is operating. The transformers are
grounded to the valve covers. Personal injury or
death may result and the ignition system will be
damaged if the valve covers are removed during
engine operation. The engine will not operate
without the valve covers.
Maintenance of the spark plugs is required in order
to achieve the following benefits:
• Normal fuel consumption
• Normal level of emissions
• Maximum service life of the spark plugs
The service life of the spark plugs is affected by
fouling due to deposits from the oil and by peak
voltage. Maintenance of the ignition system is also
affected by voltage. Higher voltage is required by
higher inlet manifold air pressure and a higher
compression ratio. Higher voltage reduces the
service life of components such as spark plugs,
wires, and transformers.
g00712201
Illustration 60
(1) Wiring harness
(2) Transformer assembly
(3) Spark plug
SEBU6883-08
Removing the Spark Plug
NOTICE
Do not pull on the wires. Damage to the wiring harness
may result.
1. Disconnect wiring harness (1) from transformer
assembly (2).
2. Remove transformer assembly (2).
3. Ensure that the area around spark plug (3) is
clean. Use a 2P-5481 Deep Well Socket with an
extension in order to remove spark plug (3).
Cleaning the Spark Plug
Clean the spark plug with a nonmetallic brush.
Inspect the spark plug for the following conditions:
corrosion, pitting, and wear. If the spark plug is in
good condition, the spark plug may be installed. If
the spark plug is not in good condition, install a new
spark plug. Check the spark plug gap before installing
the spark plug. The spark plug gap depends on the
compression ratio of the engine.
• Set spark plug gap to 0.28 ± 0.05 mm
(0.011 ± 0.002 inch) for the compression ratio of
11.3:1.
• Set spark plug gap to 0.46 ± 0.05 mm
(0.018 ± 0.002 inch) for the compression ratio of
8.5:1.
Installing the Spark Plug
1. Install the spark plug.
2. Tighten spark plug (3) to 30 ± 4 N·m (22 ± 3 lb ft).
3. Install transformer assembly (2). Ensure that the
transformer assembly is aligned with the wiring
harness socket. Ensure that the wiring harness
socket is oriented toward the center of the engine.
4. Connect wiring harness (1).
i01005974
Ignition System Timing -
Check/Adjust
SMCS Code: 1550-025; 1550-535
After maintenance has been performed on the
ignition system, check the timing of the ignition
system. Adjust the timing, if necessary.
SEBU6883-08 81
Maintenance Section
Ignition System Transformer Resistance - Test

The optimum ignition timing for a gas engine varies • Loose connections
according to several factors:
Inspect the following components:
• Compression ratio of the engine
• Piping between the air cleaner and the turbocharger
• Inlet air temperature
• Turbocharger
• Methane number of the gas
• Piping between the turbocharger and the
For the proper timing, see the Engine Performance aftercooler
publication for the engine.
• Aftercooler
Adjust the timing according to the Service Manual,
“Systems Operation/Testing and Adjusting” module. • Connection of the aftercooler to the air plenum
Consult your Caterpillar dealer for assistance.
• Connection of the air plenum to the cylinder head
i00682407
Ensure that all of the connections are secure. Ensure
Ignition System Transformer that the components are in good condition.

Resistance - Test Make repairs, if necessary. For information regarding

SMCS Code: 1550-081
The transformers produce a voltage increase. For
good operation, the connections must be clean and
secure. Inspect the transformers for the following
conditions. If any of the conditions are found, correct
removal and installation of the components, see
the Service Manual, “Disassembly and Assembly”
module. Consult your Caterpillar dealer for
assistance.
i01021379

the condition: Instrument Panel - Inspect

• Corrosion SMCS Code: 7451-040
• Dirty insulator Inspect the instrument panel for good condition.
Check the condition of all of the gauges. If a gauge
• Loose connections is broken, repair the gauge or replace the gauge
immediately.
• Moisture
Frequently monitor the following parameters during
• Open circuits normal operation:
• Short circuits • Fuel filter differential pressure
Test the resistance of the transformers. Test each
transformer at both the side with high voltage and • Inlet air restriction
the side with low voltage. See the Service Manual,
“Specifications” module for the procedure. Consult • Inlet manifold air temperature
your Caterpillar dealer for assistance.
• Jacket water temperature
i01113853 • Oil filter differential pressure
Inlet Air System - Inspect • Oil pressure
SMCS Code: 1058-040; 1071-040; 1087-040 Record the data in a log. Compare the new data to
the data that was previously recorded. Comparing
Inspect the components of the air inlet system for the new data to the recorded data will establish the
the following conditions: normal gauge readings for the engine. A gauge
reading that is abnormal may indicate a problem with
• Cracks operation or a problem with the gauge.

• Leaks
82
Maintenance Section
Jacket Water Heater - Check
i01042517
Jacket Water Heater - Check
SMCS Code: 1383-535
S/N: 6ZM1-Up
S/N: 8LW1-Up
S/N: BAZ1-Up
Jacket water heaters help to improve startability in
ambient temperatures that are below 21 °C (70 °F).
All installations that require automatic starting should
have jacket water heaters.
Check the operation of the jacket water heater. For
an ambient temperature of 0 °C (32 °F), the heater
should maintain the jacket water temperature at
approximately 32 °C (90 °F).
i02064986
Overhaul (Major)
SMCS Code: 7595-020-MJ
Scheduling a Major Overhaul
The need for a major overhaul is determined by
several factors.
• An increase of oil consumption
• An increase of crankcase blowby
• A decrease and variation of cylinder compression
The following changes in the three conditions
normally require a scheduled overhaul:
• A 300 percent increase in oil consumption
• A 200 percent increase in crankcase blowby
• A 20 percent loss of cylinder compression
Note: These indications do not require an engine
to be shut down for service. These indications
only mean that an engine should be scheduled for
service in the near future. If the engine operation
is satisfactory, an immediate overhaul is not a
requirement.
The engine does not require an overhaul if the
engine is operating within acceptable limits for
oil consumption, crankcase blowby, and cylinder
compression.
Other factors must also be considered for determining
a major overhaul:
SEBU6883-08
• The service hours of the engine
• The wear metal analysis of the lube oil
• An increase in the levels of noise and vibration
An increase of wear metals in the lube oil indicates
that the bearings and the surfaces that wear may
need to be serviced. An increase in the levels of
noise and vibration indicates that rotating parts
require service.
Note: It is possible for oil analysis to indicate a
decrease of wear metals in the lube oil. The cylinder
liners may be worn so that polishing of the bore
occurs. Also, the increased use of lube oil will dilute
the wear metals.
Monitor the engine as the engine accumulates
service hours. Consult your Caterpillar dealer about
scheduling a major overhaul.
Note: The driven equipment may also require service
when the engine is overhauled. Refer to the literature
that is provided by the OEM of the driven equipment.
Major Overhaul Information
A major overhaul includes all of the work that is done
for top end overhauls. A major overhaul includes
additional parts and labor. Additional parts and
labor are required in order to completely rebuild the
engine. In some cases, the engine is relocated for
disassembly.
For the major overhaul, all of the bearings,
seals, gaskets, and components that wear are
disassembled. The parts are cleaned and the parts
are inspected. If necessary, the parts are replaced.
The crankshaft is measured for wear. The crankshaft
may require regrinding. Alternatively, the crankshaft
may be replaced with a Caterpillar replacement part.
Your Caterpillar dealer can provide these services
and components. Your Caterpillar dealer can ensure
that the components are operating within the
appropriate specifications.
If you elect to perform an overhaul without the
services of a Caterpillar dealer, be aware of the
following recommendations.
The following definitions explain the terminology for
the services that are performed during an overhaul:
SEBU6883-08 83
Maintenance Section
Overhaul (Major)

Inspect – Inspect the components according to • Main bearings

the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable • Piston rings
Parts and Salvage Operations, SEBF8029, “Index
of Publications on Reusability or Salvage of Used • Rod ends for the control linkage of the actuator
Parts”. The guidelines were developed in order to
help Caterpillar dealers and customers to avoid • Spark plugs
unnecessary expenditures. New parts are not
required if the existing parts can still be used, • Spark plug wires
reconditioned, or repaired. If the components are
not in the reusability guidelines, refer to the Service • Transformers
Manual, “Specifications” module.
• Valve rotators
Rebuild – The component can be reconditioned in
order to comply with reusability guidelines. • Water temperature regulators
Replace – The service life of the part is exhausted. • Wiring harnesses
The part may fail before the next maintenance
interval. The part must be replaced with a part that Rebuilding of Components
meets functional specifications. The replacement
part may be a new part, a CAT remanufactured part, Rebuild the following components during the major
a rebuilt part, or a used part. Some worn components overhaul. If the components cannot be rebuilt,
may be exchanged with your Caterpillar dealer. replace the components.
Consult your Caterpillar dealer about repair options
for your engine. • Carburetor
Replacing of Components • Cylinder packs
Note: The cylinder head may be rebuilt, when • Exhaust bypass
possible.
• Gas regulator
Replace the following components during the major
overhaul. • Inlet air piping
• Alternator • Oil pump
• Alternator and fan drive belts • Starting motor
• Camshaft bearings • Turbocharger
• Connecting rod bearings • Water pumps
• Crankshaft bearings Inspecting Components
• Crankshaft seals Inspect the following components according to
the instructions that are in Caterpillar reusability
• Crankshaft vibration damper publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index
• Cylinder liners of Publications on Reusability or Salvage of Used
Parts”.
• Cylinder head and gaskets
• Aftercooler
• Exhaust manifold
• Camshafts
• Gaskets and seals
• Camshaft followers
• Gear train bearings
• Connecting rods
• Governor
• Crankshaft
• Hoses and clamps
84 SEBU6883-08
Maintenance Section
Overhaul (Top End)

• Gears of the gear train Unexpected problems may be found during a top
end overhaul. Plan to correct these problems, if
• Gear train bushings necessary.

• Governor • Buildup in the cylinders from excessive oil

consumption
• Inlet air piping
• Buildup in the cylinders from contamination of the
• Oil cooler fuel

• Oil pump • Plugging of the aftercooler from coolant that is

poorly maintained
• Pistons
• Plugging of the aftercooler from contamination of
• Transformers the inlet air

i02064994
Overhaul (Top End)
SMCS Code: 7595-020-TE
Scheduling a Top End Overhaul
Top end overhauls are scheduled according to
the recession of the exhaust valve stems. This
measurement provides an accurate indication of the
rate of valve wear. This measurement can be used to
predict when a cylinder head requires replacement.
For more information, refer to this Operation and
Maintenance Manual, “Valve Stem Projection -
Measure/Record” topic.
Note: The generator or the driven equipment may
also require service when the engine overhaul is
performed.
• Degradation of the oil cooler from hydrogen sulfide
in the fuel
Inspect the following components according to
the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index
of Publications on Reusability or Salvage of Used
Parts”.
Your Caterpillar dealer can provide these services
and components. Your Caterpillar dealer can ensure
that the components are operating within the
appropriate specifications.
If you elect to perform an overhaul without the
services of a Caterpillar dealer, be aware of the
following recommendations.
The following definitions explain the terminology for
the services that are performed during an overhaul:

Top End Overhaul Information Inspect – Inspect the components according to

A top end overhaul involves servicing the cylinder
heads and turbochargers. Also, some other engine
components are inspected.
Top end overhauls require more tools than preventive
maintenance. The following tools are needed for
restoring the engine to factory specifications:
• Torque wrenches
• Dial indicators
• Accurate measurement tools
the instructions that are in Caterpillar reusability
publications. Refer to Guidelines for Reusable
Parts and Salvage Operations, SEBF8029, “Index
of Publications on Reusability or Salvage of Used
Parts”. The guidelines were developed in order to
help Caterpillar dealers and customers to avoid
unnecessary expenditures. New parts are not
required if the existing parts can still be used,
reconditioned, or repaired. If the components are
not in the reusability guidelines, refer to the Service
Manual, “Specifications” module.
Rebuild – The component can be reconditioned in
order to comply with reusability guidelines.

• Cleaning equipment
• Rebuilding equipment
Caterpillar dealers are equipped with these tools.
Caterpillar dealers can provide a flat rate price for
a top end overhaul.
SEBU6883-08
Replace – The service life of the part is exhausted.
The part may fail before the next maintenance
interval. The part must be replaced with a part that
meets functional specifications. The replacement
part may be a new part, a CAT remanufactured part,
a rebuilt part, or a used part. Some worn components
may be exchanged with your Caterpillar dealer.
Consult your Caterpillar dealer about repair options
for your engine.
Replacing of Components
Note: The cylinder head may be rebuilt, when
possible.
Replace the following components during a top end
overhaul.
• Alternator and fan drive belts
• Cylinder heads and gaskets
• Hoses and clamps
• Rod ends for the control linkage of the actuator
• Spark plugs
• Spark plug wires
• Water temperature regulator
Rebuilding of Components
Rebuild the following components during a top end
overhaul:
• Carburetor
• Gas regulator
• Starting motor
• Turbocharger
• Water pumps
Note: Periodic inspection of the turbocharger is
recommended for determining when the turbocharger
will require an overhaul. In a few applications, the
turbocharger may require rebuilding prior to the top
end overhaul. An example is an application with
loads that vary frequently. In these cases, rebuilding
the turbocharger normally occurs separately from
rebuilding the cylinder heads. Some applications
can operate longer before the turbocharger requires
rebuilding. Only experience can determine the actual
need.
85
Maintenance Section
Overhaul (Top End)
Inspecting of Components
Clean the following components. Pressure test the
components. Replace the components, if necessary:
• Aftercooler core (if equipped)
• Oil cooler core
Note: It is difficult to clean the aftercooler core when
maintenance is not performed.
Note: This procedure may be used for cleaning both
the aftercooler core and the oil cooler core.
1. Remove the core. For the procedure, refer to the
Service Manual, “Disassembly and Assembly”
module.
2. Turn the core upside-down in order to remove
debris.
NOTICE
Do not use a high concentration of caustic cleaner to
clean the core. A high concentration of caustic cleaner
can attack the internal metals of the core and cause
leakage. Only use the recommended concentration of
cleaner.
NOTICE
Do not use a high pressure spray for cleaning the fins
of the core. A high pressure spray can damage the
surface of the fins and reduce the flow of air through
the core.
3. Back flush the core with cleaner.
Caterpillar recommends the use of Hydrosolv
liquid cleaner. Use a two to five percent
concentration of the cleaner at temperatures up
to 93 °C (200 °F). Refer to Application Guide,
NEHS0526 or consult your Caterpillar dealer for
more information.
4. Steam clean the core in order to remove any
residue. Flush the fins of the core. Remove any
other trapped debris.
5. Wash the core with hot, soapy water. Rinse the
core thoroughly with clean water.
86
Maintenance Section
Overhaul Considerations
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
6. Dry the core with compressed air. Direct the air in
the reverse direction of the normal flow.
Note: The test pressure for the oil cooler is 790 kPa
(115 psi). The maximum differential pressure of water
for the aftercooler is 44 kPa (6 psi). The maximum
differential pressure of air for the aftercooler is
5.1 kPa (0.74 psi).
7. Inspect the core in order to ensure cleanliness.
Pressure test the core. Many shops that service
radiators are equipped to perform pressure tests.
If necessary, repair the core.
8. Install the core. For the procedure, refer to the
Service Manual, “Disassembly and Assembly”
module.
For more information on cleaning the cores, consult
your Caterpillar dealer.
Exhaust Bypass
Inspect the condition of the exhaust bypass (if
equipped). Recondition the component, if necessary.
Refer to this Operation and Maintenance Manual,
“Exhaust Bypass - Inspect” topic (Maintenance
Section).
Governor
Inspect the governor for proper operation. Make any
repairs that are necessary.
Transformers
The transformers produce a voltage increase. For
good operation, the connections must be clean and
secure. Inspect the transformers for the following
conditions:
• Dirty insulator
• Loose connections
• Loose connector
• Moisture
SEBU6883-08
Test the resistance of the transformers according to
the Service Manual, “Specifications” module. Consult
your Caterpillar dealer for assistance.
i02049051
Overhaul Considerations
SMCS Code: 7595-043
Overhaul Information
An overhaul is replacing the major worn components
of the engine. An overhaul is a maintenance interval
that is planned. The engine is rebuilt with certain
rebuilt parts or new parts that replace the worn parts.
An overhaul also includes the following maintenance:
• Inspection of all the parts that are visible during
the disassembly
• Replacement of the seals and gaskets that are
removed
• Cleaning of the internal passages of the engine
and the engine block
Most owners will save money by overhauling the
engine at the intervals that are recommended in
this Operation and Maintenance Manual. It is not
practical to wait until the engine exhibits symptoms
of excessive wear or failure. It is not less costly to
wait. A planned overhaul before failure may be the
best value for the following reasons:
• Costly unplanned downtime can be avoided.
• Many original parts can be reused according to the
guidelines for reusable parts.
• The service life of the engine can be extended
without the risk of a major catastrophe due to
engine failure.
• Achieve the best cost/value relationship per hour
of extended service life.
Overhaul Intervals
Top end overhauls are determined by the projection of
exhaust valve stems. Major overhauls are determined
by cylinder compression, crankcase blowby, oil
consumption, and results of S·O·S oil analysis.
Some other factors that are important for determining
the overhaul intervals include the following
considerations:
• Performance of preventive maintenance
SEBU6883-08
• Use of recommended lubricants
• Use of recommended coolants
• Use of recommended fuels
• Proper installation
• Operating conditions
• Operation within acceptable limits
• Engine load
• Engine speed
Note: To avoid oil problems, engines that are
turbocharged and aftercooled must be operated at a
minimum of 60 percent of rated load.
Generally, engines that are operated at a reduced
load and/or speed achieve more service life before
an overhaul. However, this is for engines that are
properly adjusted, operated and maintained.
Overhaul Inspection
Refer to the Service Manual for the disassembly and
assembly procedures that are necessary in order
to perform the required maintenance on the items
that are listed. Consult your Caterpillar dealer for
assistance.
To determine the reusability publications that are
needed to inspect the engine, refer to Guidelines for
Reusable Parts and Salvage Operations, SEBF8029,
“Index of Publications on Reusability or Salvage of
Used Parts”.
The Guidelines For Reusable Parts and Salvage
Operations is part of an established Caterpillar
parts reusability program. These guidelines were
developed in order to assist Caterpillar dealers and
customers reduce costs by avoiding unnecessary
expenditures for new parts. If the engine parts comply
with the established inspection specifications, the
parts can be reused. New parts are not necessary if
the old parts can be reused, repaired, or salvaged.
If the parts are not within the inspection specifications,
the parts should be salvaged, repaired, replaced,
or exchanged. The use of out-of-spec parts could
result in unscheduled downtime and/or costly repairs.
The use of out-of-spec parts can also contribute to
increased fuel consumption and reduction of engine
efficiency.
Your Caterpillar dealer can provide the parts that are
needed to rebuild the engine at the least possible
cost.
87
Maintenance Section
Overhaul Considerations
Overhaul Programs
An economical way to obtain most of the parts
that are needed for overhauls is to use Caterpillar
remanufactured parts. Caterpillar remanufactured
parts are available at a fraction of the cost of new
parts. These parts have been rebuilt by Caterpillar
and certified for use. The following components are
examples of the remanufactured parts:
• Alternators
• Connecting rods
• Crankshafts
• Cylinder heads
• Oil Pumps
• Starting motors
• Turbochargers
• Water pumps
Consult your Caterpillar dealer for details and for a
list of the remanufactured parts that are available.
Your Caterpillar dealer may be offering a variety of
overhaul options.
A Flat Rate Overhaul guarantees the maximum price
that you will pay for an overhaul. Flat rate prices on
preventive maintenance programs or major repair
options are available from many servicing dealers
for all Caterpillar Engines. Consult your Caterpillar
dealer in order to schedule a before failure overhaul.
Overhaul Recommendation
Caterpillar recommends a scheduled overhaul in
order to minimize downtime. A scheduled overhaul
will provide the lowest cost and the greatest value.
Schedule an overhaul with your Caterpillar dealer.
Overhaul programs vary between dealers. To obtain
specific information about the types of overhaul
programs and services, consult your Caterpillar
dealer.
88
Maintenance Section
Power Take-Off Clutch - Check/Adjust/Lubricate
i01506009
Power Take-Off Clutch -
Check/Adjust/Lubricate
SMCS Code: 3055-036; 3055-086
NOTICE
New power take-offs should have the clutch adjust-
ment checked before being placed into service. The
clutch adjustment should be checked again after the
first ten hours of operation. New clutch plates have a
“wear in” period, and the clutch may require several
adjustments until the new plates are “worn in”.
g00781502
Illustration 61
(1) Instruction plate
(2) Serial number plate
Check the clutch adjustment regularly after “wear in”.
Heavy-duty applications which have engagements
that are frequent and relatively long periods of
clutch slippage require more frequent adjustment
than light-duty applications. The operating torque
should be measured in order to determine if a clutch
adjustment is required.
Refer to the OEM information and instruction plate
(1) for instructions on lubrication, adjustment, and
other recommendations for service. Perform the
maintenance that is specified on the instruction plate.
Do not operate the engine with the Instruction
Plate cover removed from the clutch. Personal
injury may result.
If the clutch is damaged to the point of burst fail-
ure, expelled pieces can cause personal injury to
anyone in the immediate area. Proper safeguards
must be followed to help prevent accidents.
SEBU6883-08
i02559063
Radiator - Clean
SMCS Code: 1353-070
Note: Adjust the frequency of cleaning according to
the effects of the operating environment.
Inspect the radiator for these items: damaged fins,
corrosion, dirt, grease, insects, leaves, oil, and other
debris. Clean the radiator, if necessary.
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the air
nozzle is deadheaded.
Pressurized air is the preferred method for removing
loose debris. Direct the air in the opposite direction
of the fan’s air flow. Hold the nozzle approximately
6 mm (0.25 inch) away from the fins. Slowly move the
air nozzle in a direction that is parallel with the tubes.
This will remove debris that is between the tubes.
Pressurized water may also be used for cleaning.
The maximum water pressure for cleaning purposes
must be less than 275 kPa (40 psi). Use pressurized
water in order to soften mud. Clean the core from
both sides.
Use a degreaser and steam for removal of oil and
grease. Clean both sides of the core. Wash the core
with detergent and hot water. Thoroughly rinse the
core with clean water.
After cleaning, start the engine and accelerate the
engine to high idle rpm. This will help in the removal
of debris and drying of the core. Stop the engine.
Use a light bulb behind the core in order to inspect
the core for cleanliness. Repeat the cleaning, if
necessary.
Inspect the fins for damage. Bent fins may be opened
with a “comb”. Inspect these items for good condition:
welds, mounting brackets, air lines, connections,
clamps, and seals. Make repairs, if necessary.
For more detailed information on cleaning and
inspection, refer to Special Publication, SEBD0518,
“Know Your Cooling System”.
SEBU6883-08 89
Maintenance Section
Speed Sensor - Clean/Inspect

i01511915 • Longer service life for the generator set

Speed Sensor - Clean/Inspect
SMCS Code: 1907-040; 1907-070
• Minimum of expensive repairs
Your Caterpillar dealer can help you to establish an
effective Preventive Maintenance Program for your
generator set. Consult your Caterpillar dealer for
details.

Maintenance and Operation

Procedures

The high voltage that is produced by an operating

generator set can cause severe injury or death.
Before performing any maintenance or repairs,
ensure that the generator will not start.
g00784740
Illustration 62
Speed sensors
Place the engine control switch in the “OFF” posi-
tion. Attach “DO NOT OPERATE” tags to all start-
1. Remove the speed sensor from the flywheel ing controls. Disconnect the batteries or disable
housing. Check the condition of the end of the starting system. Lock out all switchgear and
the magnet. Check for signs of wear and automatic transfer switches that are associated
contaminants. with the generator.

2. Clean the metal shavings and other debris from
the face of the magnet.
3. Install the speed sensor and adjust the speed
sensor according to the engine’s Specifications
module.
i01038735
The recommended maintenance for the engine is
listed in this Operation and Maintenance Manual,
“Maintenance Interval Schedule (Standby Generator
Set Engines)” (Maintenance Section).
For the recommended generator maintenance, see
the Operation and Maintenance Manual for the
generator and the control panel.

Standby Generator Maintenance and Repair

Set Maintenance
Recommendations
SMCS Code: 4450-041
A standby generator set may not need to be used
very often. However, the generator set is usually
needed for operation in an emergency situation.
Maintenance of the standby generator set is very
important for the following reasons:
The maintenance that is recommended for Every
Week can be performed by an authorized operator.
The maintenance that is recommended for the
subsequent maintenance intervals must be
performed by an authorized service technician or by
your Caterpillar dealer.
Unless other instructions are provided, perform
maintenance and repairs under the following
conditions:

• The generator set must always be in excellent • The engine is stopped.

operating condition.
• The starting system is disabled.
• The generator set must be ready to work under
load at any time. • The generator does not pose an electrical shock
hazard.
Establishing a Preventive Maintenance Program will
provide these benefits:

• Maximum availability of the standby generator set

90
Maintenance Section
Starting Motor - Inspect
Operation
To ensure proper operation, the generator set must be
exercised regularly. For instructions on operating the
generator set, see the Operation and Maintenance
Manual for the generator set control panel.
For these operation procedures, follow the
instructions that are provided in this Operation and
Maintenance Manual, “Operation Section”: starting
the engine, engine operation, and stopping the
engine.
Record Keeping
Maintain a record in order to document these items:
gauge readings, maintenance that is performed,
problems, and repairs.
Space Heaters
Moisture causes damage to generators and other
electrical equipment. Make every effort to keep the
generator set as dry as possible.
Generators can operate without problems in humid
environments. However, problems can occur when
the generator is inactive. Moisture can condense on
the windings. This can result in poor performance.
Also, damage to the windings can occur.
Use space heaters in order to help keep the windings
dry. When the generator is not active, ensure that the
space heaters are operating. When the generator is
operating, turn OFF the space heaters.
i01113939
Starting Motor - Inspect
SMCS Code: 1451-040; 1453-040
If the starting motor fails, the engine may not start in
an emergency situation. A scheduled inspection of
the starting motor is recommended.
The starting motor pinion and the flywheel ring gear
must be in good condition in order for the engine
to start properly. The engine will not start if the
starting motor pinion does not engage the flywheel
ring gear. The teeth of the starting motor pinion and
the flywheel ring gear can be damaged because of
irregular engagement.
Inspect the starting motor for proper operation. Listen
for grinding when the engine is started. Inspect the
teeth of the starting motor pinion and the flywheel
ring gear. Look for patterns of wear on the teeth. Look
for teeth that are broken or chipped. If damaged teeth
are found, the starting motor pinion and the flywheel
ring gear must be replaced.
SEBU6883-08
Electric Starting Motor
Note: Problems with the electric starting motor can
be caused by the following conditions: malfunction of
the solenoid and malfunction of the electric starting
system.
Inspect the electrical system for the following
conditions:
• Loose connections
• Corrosion
• Wires that are worn or frayed
• Cleanliness
Make repairs, if necessary.
Air Starting Motor
Personal injury or death can result from improp-
erly checking for a leak.
Always use a board or cardboard when checking
for a leak. Escaping air or fluid under pressure,
even a pin-hole size leak, can penetrate body tis-
sue causing serious injury, and possible death.
If fluid is injected into your skin, it must be treated
immediately by a doctor familiar with this type of
injury.
Inspect all of the components in the air circuit for
the starting motor. Inspect all of the air lines and
connections for leaks.
If the teeth of the starting motor pinion and/or the
flywheel ring gear are damaged, the air circuit for
the starting motor must be examined in order to
determine the cause of the problem.
Removal and Installation of the
Starting Motor
Refer to the Service Manual, “Disassembly and
Assembly” module for information on removing the
starting motor and installing the starting motor.
Consult your Caterpillar dealer for assistance.
SEBU6883-08
i01012850
Turbocharger - Inspect
SMCS Code: 1052-040
Periodic inspection and cleaning is recommended
for the turbocharger.
Fouling of the turbine wheels can contribute to loss of
engine power and overall loss of engine efficiency.
If the turbocharger fails during engine operation,
damage to the turbocharger compressor wheel
and/or to the engine may occur. Damage to the
turbocharger compressor wheel could allow parts
from the compressor wheel to enter an engine
cylinder. This can cause additional damage to the
pistons, the valves, and the cylinder head.
NOTICE
Turbocharger bearing failures can cause large quan-
tities of oil to enter the air inlet and exhaust systems.
Loss of engine lubricant can result in serious engine
damage.
Minor leakage of a turbocharger housing under ex-
tended low idle operation should not cause problems
as long as a turbocharger bearing failure has not oc-
curred.
When a turbocharger bearing failure is accompanied
by a significant engine performance loss (exhaust
smoke or engine rpm up at no load), do not continue
engine operation until the turbocharger is repaired or
replaced.
An inspection of the turbocharger can minimize
unscheduled downtime. Also, the chance for potential
damage to other engine parts is reduced.
Note: Turbocharger components require clearances
that are precise. The turbocharger cartridge must be
balanced due to high rpm.
The following conditions can cause the turbocharger
to be out-of-balance:
• The buildup of deposits
• Chipping and/or flaking of deposits
If the turbocharger must be removed for inspection,
use caution. Do not break deposits from the turbine
wheel. Do not attempt to clean the turbine wheel. For
options regarding removal, installation, repair and
replacement, see the Service Manual or consult your
Caterpillar dealer.
91
Maintenance Section
Turbocharger - Inspect
1. Remove the exhaust outlet piping and remove
the air inlet piping from the turbocharger. Visually
inspect the piping for the presence of oil.
2. Turn the compressor wheel and the turbine wheel
by hand. The assembly should turn freely. Inspect
the compressor wheel and the turbine wheel for
contact with the turbocharger housing. There
should not be any visible signs of contact between
the turbine wheel or compressor wheel and the
turbocharger housing. If there is any indication of
contact between the rotating turbine wheel or the
compressor wheel and the turbocharger housing,
the turbocharger should be reconditioned.
3. Check the compressor wheel for cleanliness.
If only the blade side of the wheel is dirty, dirt
and/or moisture is passing through the air filtering
system. If oil is found only on the back side of the
wheel, there is a possibility of a failed turbocharger
oil seal.
The presence of oil may be the result of extended
engine operation at low idle. The presence of oil
may also be the result of a restriction of the line for
the inlet air (plugged air filters), which causes the
turbocharger to slobber.
Note: Deposits can accumulate on the turbine wheel.
The turbine wheel will become unbalanced when the
deposits flake off. The turbocharger cartridge must
be replaced when this occurs. However, remove
deposits from the housing. This will prevent wear on
the blades of the turbine wheel.
4. Inspect the turbine wheel for deposits. If deposits
of 25 mm (1/16 inch) thickness are found or if
the turbine is in contact with the housing, the
turbocharger must be disassembled and cleaned.
The deposits can be very difficult to remove.
5. Inspect the bore of the turbine housing for
corrosion and deposits.
6. Clean the turbocharger compressor housing with
standard shop solvents and a soft bristle brush.
7. Check the clearances of the turbocharger bearing.
Compare the clearances to the Service Manual,
“Specifications”. If the clearances are not within
the specifications, the turbocharger must be
repaired.
8. Fasten the air inlet piping and the exhaust outlet
piping to the turbocharger housing.
92 SEBU6883-08
Maintenance Section
Valve Stem Projection - Measure/Record

i01360109

Valve Stem Projection -

Measure/Record
SMCS Code: 1105-082

Valve Recession – The valves and the valve seats

are worn over time. This causes the valves to recede
into the cylinder head. This condition is called “valve
recession”.

The exhaust valves and valve seats show the

greatest wear due to high operating temperatures.
The top end overhaul is normally scheduled
according to the exhaust valve recession.

It is difficult to obtain an accurate measurement of

valve recession inside the cylinder head. Use the
following method in order to determine the valve
recession:

1. Remove the valve cover. For instructions, see the

Service Manual, “Disassembly and Assembly”
module.

2. Move the rocker arm from the top of the valve

stem.

3. Use a depth micrometer. Obtain the measurement

from the tip of the valve stem to the cylinder head.
Obtain this measurement for each exhaust valve.

Make several copies of this Operation and

Maintenance Manual, “Valve Data Sheet” (Reference
Materials Section). Record the measurements on
the sheets.

• The projection of the exhaust valve stems

should be measured after completion of the initial
start-up tests and the engine commissioning. This
measurement is the baseline. The baseline is a
reference for subsequent measurements.

• Measure the projection of the exhaust valve

rotators at the first oil change interval. Illustration
63 shows schedules for determining subsequent
intervals.
SEBU6883-08
Illustration 63
(A) Schedule (Y) Valve recession in millimeters (inches)
(B) Schedule (X) Hours of operation
(C) Schedule (1) 0.254 mm (0.0100 inch)
To determine intervals, use the point on the graph in
Illustration 63 that is closest to the measurement for
each cylinder.
For example, suppose that the measurement that
was obtained at the initial oil change shows a valve
recession of approximately 0.152 mm (0.0060 inch).
According to Schedule (C), the next interval for
measuring that cylinder is at 5000 service hours.
Another cylinder may have a valve recession of
approximately 0.254 mm (0.0100 inch). According
to Schedule (A), the next interval for measuring that
cylinder is at 3000 service hours.
• After 70 percent of the maximum limit has been
reached, measure the projection of the exhaust
valve stems at every 750 hours of operation
(turbocharged engines). For Naturally aspirated
engines, perform the measurement at every 1500
hours of operation.
• Plan for the top end overhaul as the valve
stem projection approaches the maximum limit.
Perform the top end overhaul when the valve stem
projection has increased by a total of 2.3 mm
(0.09 inch). Do not allow the valve recession
to exceed this limit. The valve head can break.
This will cause severe damage in the combustion
chamber and the turbocharger.
93
Maintenance Section
Walk-Around Inspection
g00320513
(2) 0.218 mm (0.0086 inch)
(3) 0.152 mm (0.0060 inch)
Consult your Caterpillar dealer for assistance.
i01492446
Walk-Around Inspection
SMCS Code: 1000-040
Inspect the Engine for Leaks and
for Loose Connections
A walk-around inspection should only take a few
minutes. When the time is taken to perform these
checks, costly repairs and accidents can be avoided.
For maximum engine service life, thoroughly inspect
the engine room before starting the engine. Look for
items such as leaks, loose bolts, loose connections
and trash buildup. Make repairs, as needed.
• The guards must be in the proper place. Repair
damaged guards or replace missing guards.
• Wipe all caps and plugs before the engine is
serviced in order to reduce the chance of system
contamination.
94
Maintenance Section
Walk-Around Inspection
NOTICE
For any type of leak, clean up the fluid. If leaking is ob-
served, find the source and correct the leak. If leaking
is suspected, check the fluid levels more often than
recommended until the leak is found or fixed, or until
the suspicion of a leak is proved to be unwarranted.
NOTICE
Accumulated grease and/or oil on an engine or deck is
a fire hazard. Remove this debris with steam cleaning
or high pressure water.
• Ensure that cooling lines are properly clamped.
Check for leaks. Check the condition of all pipes.
• Inspect the water pumps for coolant leaks.
Note: The water pump seal is lubricated by coolant
in the cooling system. It is normal for a small amount
of leakage to occur when the engine cools and the
parts contract.
Excessive coolant leakage may indicate the need
to replace the water pump seal. For instructions
on removal and installation of water pumps and/or
seals, refer to the Service Manual, “Disassembly and
Assembly” module for the engine or consult your
Caterpillar dealer.
• Inspect the lubrication system for leaks at the front
crankshaft seal, the rear crankshaft seal, the oil
pan, the oil filters and the valve covers.
NEVER use a flame to check for gas leaks. Use a
gas detector.
An open flame can ignite mixtures of air and fuel.
This will cause explosion and/or fire which could
result in severe personal injury or death.
• Check the fuel system for leaks. Look for loose fuel
line clamps.
• Inspect the piping for the air inlet system and the
elbows for cracks and for loose clamps.
• Inspect the wiring and the wiring harnesses for
loose connections and for worn wires or frayed
wires.
• Inspect the ground straps for good connections
and for good condition.
• Check the condition of the gauges. Replace any
gauge that is damaged. Replace any gauge that
can not be calibrated.
SEBU6883-08
• Inspect the exhaust system for leaks. If a leak is
found, make repairs.
i01041757
Walk-Around Inspection
(Exercise Inspection of
Standby Generator Set
Engines)
SMCS Code: 1000-040
NEVER use a flame to check for gas leaks. Use a
gas detector.
An open flame can ignite mixtures of air and fuel.
This will cause explosion and/or fire which could
result in severe personal injury or death.
1. Perform the procedures that are described in
this Operation and Maintenance Manual, “Before
Starting Engine” topic (Operation Section).
2. Start the engine according to the instructions in
this Operation and Maintenance Manual, “Engine
Starting” topic (Operation Section).
NOTICE
For any type of leak (coolant, lube, or fuel) clean up the
fluid. If leaking is observed, find the source and correct
the leak. If leaking is suspected, check the fluid levels
more often than recommended until the leak is found
or fixed, or until the suspicion of a leak is proved to be
unwarranted.
3. Perform an inspection of the installation after
the engine is started. Look for leaks. Listen for
unusual noises.
• Check the engine oil level when the engine is
operating at low idle rpm. Observe the oil level
on the “LOW IDLE” side of the oil level gauge
(dipstick).
• Inspect the lubrication system for leaks at the oil
pan, the oil filter, and the valve covers.
• Inspect the cooling system for leaks at the hose
connections.
• Check the fuel system for leaks with a gas
detector.
• Inspect the piping for the air inlet system and
the elbows for cracks and for loose clamps.
SEBU6883-08
• Inspect the exhaust system for leaks.
• If the enclosure has louvers, inspect the louvers
for proper operation.
• Observe the gauges. Ensure the correct
readings for the engine rpm. Record the engine
oil pressure and the jacket water temperature.
• Record the data for the performance of the
generator. See the Operation and Maintenance
Manual for the generator and the control panel.
4. After exercising the generator set, stop the engine
according to this Operation and Maintenance
Manual, “Engine Stopping” topic (Operation
Section).
5. Perform the procedures that are described in
this Operation and Maintenance Manual, “After
Stopping Engine” topic (Operation Section).
6. Ensure that the control switches are in the correct
position for automatic starting of the generator set.
i02624237
Water Pump - Inspect
SMCS Code: 1361-040
A failed water pump might cause severe engine
overheating problems that could result in cracks in
the cylinder head, a piston seizure or other potential
damage to the engine.
Visually inspect the water pump for leaks. If leaking
of the water pump seals is observed, replace all of
the water pump seals. Refer to two articles in the
Disassembly and Assembly Manual, “Water Pump
- Disassemble and Water Pump - Assemble” for
the disassembly and assembly procedure. If it is
necessary to remove the water pump, refer to two
articles in the Disassembly and Assembly Manual,
“Water Pump - Remove and Water Pump - Install”.
Inspect the water pump for wear, cracks, pin holes
and proper operation. Refer to the Parts Manual
for the correct part numbers for your engine or
consult your Caterpillar dealer if repair is needed or
replacement is needed.
95
Maintenance Section
Water Pump - Inspect
i01023425
Water Temperature Regulator -
Replace
SMCS Code: 1355-510
Replace the water temperature regulators before
the water temperature regulators fail. This is a
recommended preventive maintenance practice.
Replacing the water temperature regulators reduces
the chances for unscheduled downtime.
A water temperature regulator that fails in a
partially opened position can cause overheating or
overcooling of the engine.
A water temperature regulator that fails in the closed
position can cause excessive overheating. Excessive
overheating could result in cracking of the cylinder
head or a seizure of the pistons.
A water temperature regulator that fails in the open
position will cause the engine operating temperature
to be too low during partial load operation. Low
engine operating temperatures during partial loads
could cause an excessive carbon buildup inside the
cylinders. This excessive carbon buildup could result
in an accelerated wear of the piston rings and wear
of the cylinder liner. Also, a low temperature can
allow moisture to condense in the oil. This can form
damaging acids.
NOTICE
Failure to replace the water temperature regulators
on a regularly scheduled basis could cause severe
engine damage.
Never operate the engine without the water tempera-
ture regulators installed.
If the water temperature regulator is installed incor-
rectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature reg-
ulator is installed in the original position.
For the procedure to replace the water temperature
regulators, see the Service Manual, “Disassembly
and Assembly” module. Consult your Caterpillar
dealer for assistance.
Note: If only the water temperature regulators are
replaced, drain the coolant from the cooling system to
a level that is below the water temperature regulator
housing.
96 SEBU6883-08
Reference Information Section
Customer Service

Reference Information Latin America, Mexico, Carribean

Caterpillar Americas Co.
Section 701 Waterford Way, Suite 200
Miami, FL 33126-4670
USA
Phone: 305-476-6800
Customer Service Fax: 305-476-6801

Europe, Africa, and Middle East

i02097871
Caterpillar Overseas S.A.
Customer Assistance 76 Route de Frontenex
P.O. Box 6000
SMCS Code: 1000; 4450 CH-1211 Geneva 6
Switzerland
Phone: 22-849-4444
USA and Canada Fax: 22-849-4544
When a problem arises concerning the operation of Far East
an engine or concerning the service of an engine, Caterpillar Asia Pte. Ltd.
the problem will normally be managed by the dealer 7 Tractor Road
in your area. Jurong, Singapore 627968
Republic of Singapore
Your satisfaction is a primary concern to Caterpillar Phone: 65-662-8333
and to Caterpillar dealers. If you have a problem that Fax: 65-662-8302
has not been handled to your complete satisfaction,
follow these steps: China
Caterpillar China Ltd.
1. Discuss your problem with a manager from the 37/F., The Lee Gardens
dealership. 33 Hysan Avenue
Causeway Bay
2. If your problem cannot be resolved at the dealer G.P.O. Box 3069
level without additional assistance, use the phone Hong Kong
number that is listed below to talk with a Field Phone: 852-2848-0333
Service Coordinator: Fax: 852-2848-0440
1-800-447-4986 Japan
Shin Caterpillar Mitsubishi Ltd.
The normal hours are from 8:00 to 4:30 Monday SBS Tower
through Friday Central Standard Time. 10-1, Yoga 4-Chome
Setagaya-Ku, Tokyo 158-8530
3. If your needs have not been met still, submit the Japan
matter in writing to the following address: Phone: 81-3-5717-1150
Fax: 81-3-5717-1177
Caterpillar Inc.
Manager, Customer Service, Engine Division Japan
Mossville Bldg AC Caterpillar Power Systems, Inc.
P.O. Box 610 SBS Tower (14th floor)
Mossville, Illinois 61552-0610 4-10-1, Yoga
Setagaya-Ku, Tokyo 158-0097
Please keep in mind: probably, your problem will Phone: 81-3-5797-4300
ultimately be solved at the dealership, using the Fax: 81-3-5797-4359
dealership’s facilities, equipment, and personnel.
Therefore, follow the steps in sequence when a Australia and New Zealand
problem is experienced. Caterpillar of Australia Ltd.
1 Caterpillar Drive
Outside of the USA and of Canada Private Mail Bag 4
Tullamarine, Victoria 3043
If a problem arises outside the USA and outside Australia
Canada, and if the problem cannot be resolved at the Phone: 03-9953-9333
dealer level, consult the appropriate Caterpillar office. Fax: 03-9335-3366
SEBU6883-08 97
Reference Information Section
Customer Service

i01028392

Ordering Replacement Parts

SMCS Code: 4450; 7567

When replacement parts are required for this

product Caterpillar recommends using Caterpillar
replacement parts or parts with equivalent spec-
ifications including, but not limited to, physical
dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

Quality Caterpillar replacement parts are available

from Caterpillar dealers throughout the world.
Caterpillar dealers’ parts inventories are up-to-date.
The parts stocks include all of the parts that are
normally needed to protect your Caterpillar engine
investment.

When you order parts, please specify the following

information:

• Part number
• Part name
• Quantity
If there is a question concerning the part number,
please provide your dealer with a complete
description of the needed item.

When a Caterpillar engine requires maintenance

and/or repair, provide the dealer with all the
information that is stamped on the Information Plate.
This information is described in this Operation and
Maintenance Manual (Product Information Section).

Discuss the problem with the dealer. Inform the

dealer about the conditions of the problem and the
nature of the problem. Inform the dealer about when
the problem occurs. This will help the dealer in
troubleshooting the problem and solving the problem
faster.
98 SEBU6883-08
Reference Information Section
Reference Materials

Reference Materials
i02408969

Maintenance Records
SMCS Code: 1000; 4450

Caterpillar Inc. recommends the retention of accurate

maintenance records. Accurate maintenance records
can be used for the following purposes:

• Demonstration of compliance with the required

maintenance practices and maintenance intervals

• Determination of operating costs

• Establishment of maintenance schedules for other
engines that are operated in the same environment

Maintenance records can be used for a variety of

other business decisions that are related to engine
maintenance.

Maintenance records are a key element of a

maintenance program that is well managed. Accurate
maintenance records can help your Caterpillar dealer
to fine tune the recommended maintenance intervals
in order to meet the specific operating situation. This
should result in a lower engine operating cost.

Keep records for the following items:

Service Hours – A record of service hours is

essential to determine when the speed sensitive
components should be inspected or repaired.

Documents – These items should be easy to

obtain, and these items should be kept in the engine
history file. All of the documents should show this
information: date, service hours, fuel consumption,
unit number, and engine serial number. Keep the
following documents as proof of maintenance or
repair for warranty:

• Dealer work orders and itemized bills

• Logs of engine performance
• Maintenance logs
• Owner’s repair costs
• Owner’s receipts
• Trend charts
SEBU6883-08 99
Reference Information Section
Reference Materials

i02209903

Maintenance Log
SMCS Code: 1000; 4450

Table 18
Engine Model Customer Identifier
Serial Number Arrangement Number
Service
Service Item Date Authorization
Hours
100 SEBU6883-08
Reference Information Section
Reference Materials

i01340010

Valve Data Sheet

SMCS Code: 1000

Table 19
Engine Model Serial Number Service Hours Authorization
Cylinder Valve Location Current Stem Rotator
Cylinder Wear
Pressure Measure Baseline Baseline
1 Pushrod Side
Inlet Manifold
2 Pushrod Side
Inlet Manifold
3 Pushrod Side
Inlet Manifold
4 Pushrod Side
Inlet Manifold
5 Pushrod Side
Inlet Manifold
6 Pushrod Side
Inlet Manifold
7 Pushrod Side
Inlet Manifold
8 Pushrod Side
Inlet Manifold
9 Pushrod Side
Inlet Manifold
10 Pushrod Side
Inlet Manifold
11 Pushrod Side
Inlet Manifold
12 Pushrod Side
Inlet Manifold

i02800962 • Data Sheet, PEHJ0006, “Cat NGEO EL350

(Natural Gas Engine Oil) SAE40”
Reference Material
• Special Publication, SEBD0640, “Oil and Your
SMCS Code: 1000; 4450 Engine”
The following literature can be obtained through any • Special Publication, PEDP1129, “Listen To Your
Caterpillar dealer. Oil”

Lubricants • Special Instruction, PEHP6001, “How To Take A

Good Oil Sample”
• Data Sheet, PEHP0004, “Cat NGEO (Natural Gas
Engine Oil) SAE30 and SAE40”
SEBU6883-08
• Special Publication, PEGJ0035, “Grease Selection
Guide”
• Data Sheet, PEHJ0088, “Cat Multipurpose Grease”
• Data Sheet, PEHP0002, “Cat Advanced 3Moly
Grease”
• Data Sheet, NEHP6015, “Cat High Speed Ball
Bearing Grease”
• Special Publication, SEBU6400, “Caterpillar
Gas Engine Lubricant, Fuel, and Coolant
Recommendations”
• Special Publication, PECP9067, “One Safe
Source”
Fuels
• Data Sheet, LEKQ9360, “Internal Combustion
Engine Fuel Gases”
• Data Sheet, LEKQ2364, “US Stationary Engine
Regulations/Spark Ignited Emissions”
• Data Sheet, LEKQ5404, “Fuels Specifications
Changes”
• Application and Installation Guide, LEKQ7256,
“Fuels, Fuel Systems”
• Application and Installation Guide, LEKQ7260,
“Low Energy Fuels”
• Special Publication, SEBU6400, “Caterpillar
Gas Engine Lubricant, Fuel, and Coolant
Recommendations”
Coolants
• Data Sheet, PEHJ0040, “Cat NGEC (Natural Gas
Engine Coolant 50/50 Premix)”
• Data Sheet, PEHP9554, “Cat DEAC (Diesel
Engine Antifreeze/Coolant Concentrate)”
• Data Sheet, LEKQ8567, “Water Treatment
Recommendations for Ebullient and Solid Water
Cooled Engines”
• Special Publication, PEDP5033, “S·O·S Coolant
Analysis”
• Special Publication, SEBD0518, “Know Your
Cooling System”
• Special Publication, SEBD0970, “Coolant and Your
Engine”
101
Reference Information Section
Reference Materials
• Special Publication, SEBU6400, “Caterpillar
Gas Engine Lubricant, Fuel, and Coolant
Recommendations”
Miscellaneous
• Systems Operation, KENR5186, “G3408C and
G3412C” Engines Air/Fuel Ratio Control (NOx
Feedback)
• Troubleshooting, RENR5916, “Air/Fuel Ratio
Control”
• Service Manual, RENR1340, “G3408C Engine”
• Specifications, SENR3130, “Torque Specifications”
• Special Instruction, SMHS7001, “Assembly of Fan
Drive Pulley Assemblies”
• Special Instruction, SEHS9124, “Cleaning and
Drying of Electric Set Generators”
• Special Instruction, SEHS7332, “Do Not Operate
Tag”
• Special Instruction, SEHS7633, “Battery Test
Procedure”
• Special Instruction, SEHS7654, “Alignment-
General Instructions”
• Special Instruction, SEHS8712, “Using the
8T-2700 Blowby/Airflow Indicator Group”
• Special Instruction, SEHS9031, “Storage
Procedure for Caterpillar Products”
• Special Instruction, SEHS9298, “Installation and
Maintenance of Gaseous Fuel Filters”
• Special Instruction, REHS0371, “Installation and
Initial Start-Up Procedure for G3300 and G3400
Engines”
• Special Publication, NENG2500, “Caterpillar
Dealer Service Tools Catalog”
• Special Publication, SEBF8029, “Index to
Guidelines for Reusable Parts and Salvage
Operations”
• Special Publication, SEBF8062, “Procedure to
Inspect and Clean Air Filters”
Additional Reference Material
The “Engine Fluids Data Book” can be obtained from
the following locations: local technological society,
local library, and local college. If necessary, consult
EMA at the following address:
102 SEBU6883-08
Reference Information Section
Reference Materials

Engine Manufacturers Association i00382622

Two North LaSalle Street, Suite 2200
Chicago, Illinois, USA 60602 Warranty Information
E-mail: ema@enginemanufacturers.org
(312) 827-8700 SMCS Code: 1000
Facsimile: (312) 827-8737
Engine Protection Plans
The “Society of Automotive Engineers (SAE)
Specifications” can be found in your SAE handbook.
Extended Warranties and Service
This publication can also be obtained from the
following locations: local technological society, local Contracts
library, and local college. If necessary, consult SAE
at the following address: A wide variety of protection plans are available for
Caterpillar Engines. Consult your Caterpillar dealer
SAE International for detailed information on the specific programs and
400 Commonwealth Drive coverages that are available.
Warrendale, PA, USA 15096-0001
Telephone: (724) 776-4841 Consult your Caterpillar dealer for information on a
plan that is tailored in order to fit your requirements.
The “American Petroleum Institute Publication No.
1509” can be obtained from the following locations:
local technological society, local library, and local
college. If necessary, consult API at the following
address:

American Petroleum Institute

1220 L St. N.W.
Washington, DC, USA 20005
Telephone: (202) 682-8000

The International Organization for Standardization

(ISO) offers information and customer service
regarding international standards and standardizing
activities. ISO can also supply information on the
following subjects that are not controlled by ISO:
national standards, regional standards, regulations,
certification, and related activities. Consult the
member of ISO in your country.

International Organization for Standardization

(ISO)
1, rue de Varembé
Case postale 56
CH-1211 Genève 20
Switzerland
Telephone: +41 22 749 01 11
Facsimile: +41 22 733 34 30
E-mail: central@iso.ch
Web site: http://www.iso.ch

European classifications are established by the

Counseil International Des Machines a Combustion
(CIMAC) (International Council on Combustion
Engines).

CIMAC Central Secretariat

Lyoner Strasse 18
60528 Frankfurt
Germany
Telephone: +49 69 6603 1567
Facsimile: +49 69 6603 1566
SEBU6883-08
Index
A Cooling System Coolant Sample (Level 2) -
Actuator Control Linkage - Lubricate ..................... 57
Check the Linkage ............................................. 57
After Starting Engine ............................................. 46
Engaging the Driven Equipment ........................ 46
After Stopping Engine............................................ 49
Air Tank Moisture and Sediment - Drain................ 57
Alarms and Shutoffs .............................................. 34
Alternator - Inspect ................................................ 57
Automatic Start/Stop - Inspect (Generator Set)..... 57
B Customer Service ..................................................
Batteries - Replace ................................................ 58
Battery Charger - Check........................................ 58
Checking After Stopping .................................... 59
Checking Before Start-Up .................................. 58
Battery Electrolyte Level - Check .......................... 59
Before Starting Engine .................................... 15, 42
Air Inlet System.................................................. 42
Cooling System.................................................. 42
Driven Equipment .............................................. 42
Electrical System ............................................... 42
Fuel System ....................................................... 43
Lubrication System ............................................ 43
Starting System.................................................. 43
Walk-Around Inspection..................................... 42
Belts - Inspect/Adjust/Replace............................... 59
Adjusting the Alternator Belt .............................. 60
Adjusting the Fan Drive Belt .............................. 60
Inspection........................................................... 59
Replacement...................................................... 60
Burn Prevention..................................................... 12
Batteries............................................................. 13
Coolant............................................................... 12
Oils..................................................................... 13
C Replace the Oil Filter ......................................... 74
Carburetor Air/Fuel Ratio - Check/Adjust .............. 60
Cold Weather Starting ........................................... 44
Control Panel......................................................... 36
Control Panel for Stopping................................. 36
Remote Control Panel (Status) .......................... 37
Control Panel - Inspect .......................................... 60
Record the Data and Review the Data .............. 61
Cooling System Coolant (DEAC) - Change........... 61
Clean the Cooling System ................................. 61
Cleaning a Cooling System that has Heavy
Deposits or Plugging ........................................ 62
Drain the Cooling System .................................. 61
Fill the Cooling System ...................................... 62
Cooling System Coolant Sample (Level 1) -
Obtain .................................................................. 63
103
Index Section
Obtain .................................................................. 63
Cooling System Supplemental Coolant Additive
(SCA) - Test/Add.................................................. 64
Add the SCA, If Necessary ................................ 64
Test the Concentration of the SCA..................... 64
Crankcase Blowby - Measure/Record ................... 65
Crankshaft Vibration Damper - Inspect ................. 65
Visconic Damper................................................ 66
Crushing Prevention and Cutting Prevention ........ 14
Customer Assistance............................................. 96
Outside of the USA and of Canada.................... 96
USA and Canada ............................................... 96
96
Cylinder Pressure - Measure/Record .................... 66
D
Driven Equipment - Check..................................... 67
Driven Equipment - Inspect/Replace/Lubricate ..... 67
E
Electrical System ................................................... 16
Grounding Practices .......................................... 16
Emergency Stopping ............................................. 48
Emergency Stop Button ..................................... 48
Engine - Clean....................................................... 67
Engine Air Cleaner Element - Replace.................. 68
Cleaning the Primary Air Cleaner Elements ...... 69
Servicing the Air Cleaner Elements ................... 68
Engine Air Cleaner Service Indicator - Inspect...... 70
Test the Service Indicator................................... 70
Engine Air Precleaner - Clean ............................... 71
Engine Crankcase Breather - Clean...................... 71
Engine Oil and Filter - Change .............................. 73
Drain the Engine Oil........................................... 73
Fill the Engine Crankcase .................................. 75
Engine Oil Level - Check ....................................... 72
Engine Oil Sample - Obtain ................................... 72
Obtain the Sample and the Analysis.................. 72
Engine Operation................................................... 47
Operating the Engine and the Driven
Equipment ........................................................ 47
Partial Load Operation ....................................... 47
Engine Performance - Test .................................... 75
Engine Protective Devices - Check ....................... 75
Visual Inspection................................................ 75
Engine Speed Governing ...................................... 41
Engine Speed/Timing Sensor - Clean/Inspect....... 76
Engine Starting ................................................ 16, 42
Engine Stopping .............................................. 16, 48
Engine Valve Lash - Inspect/Adjust ....................... 76
Engine Valve Rotators - Inspect ............................ 76
Exhaust Bypass - Inspect ...................................... 77
104
Index Section
Exhaust Piping - Inspect........................................ 77
Water Cooled Exhaust Manifolds....................... 77
F
Features and Controls ........................................... 31
Fire Prevention and Explosion Prevention ............ 13
Fire Extinguisher ................................................ 14
Lines, Tubes and Hoses .................................... 14
Foreword ................................................................. 5
California Proposition 65 Warning ....................... 4
Literature Information........................................... 4
Maintenance ........................................................ 4
Maintenance Intervals.......................................... 4
Operation ............................................................. 4
Overhaul .............................................................. 5
Safety................................................................... 4
Fuel System Fuel Filter Differential Pressure -
Check................................................................... 77
G Overhaul (Major)....................................................
Gas Pressure Regulator - Check........................... 78
Pressure of the Fuel Supply To the Carburetor.. 78
Gauges and Indicators .......................................... 28
General Hazard Information .................................. 10
Asbestos Information .......................................... 11
Containing Fluid Spillage .................................... 11
Dispose of Waste Properly ................................ 12
Fluid Penetration................................................. 11
Pressurized Air and Water .................................. 11
Governor - Inspect................................................. 78
H Fuel Consumption..............................................
Hoses and Clamps - Inspect/Replace ................... 78
Replace the Hoses and the Clamps .................. 79
Hoses and Clamps - Replace................................ 79
I Power Take-Off Clutch - Check/Adjust/Lubricate ..
Ignition System Spark Plugs - Check/Adjust/
Replace................................................................ 80
Cleaning the Spark Plug .................................... 80
Installing the Spark Plug .................................... 80
Removing the Spark Plug .................................. 80
Ignition System Timing - Check/Adjust .................. 80
Ignition System Transformer Resistance - Test ..... 81
Ignition Systems .................................................... 15
Important Safety Information ................................... 2
Inlet Air System - Inspect....................................... 81
Instrument Panel - Inspect..................................... 81
J R
Jacket Water Heater - Check ................................ 82
SEBU6883-08
L
Lifting and Storage ................................................ 26
M
Maintenance Interval Schedule (Standard) ........... 54
Maintenance Interval Schedule (Standby)............. 56
Maintenance Log ................................................... 99
Maintenance Records............................................ 98
Maintenance Section ............................................. 50
Manual Stop Procedure......................................... 48
Model View Illustrations................................... 18–19
Model Views and Specifications ............................ 18
Mounting and Dismounting.................................... 15
O
Operation Section.................................................. 26
Ordering Replacement Parts ................................. 97
82
Major Overhaul Information ............................... 82
Scheduling a Major Overhaul............................. 82
Overhaul (Top End) ............................................... 84
Scheduling a Top End Overhaul ........................ 84
Top End Overhaul Information ........................... 84
Overhaul Considerations ....................................... 86
Overhaul Information ......................................... 86
P
Performance Parameters ...................................... 31
Air/Fuel Ratio ..................................................... 31
31
Throttle Angle and Exhaust Bypass
(Wastegate)...................................................... 32
Plate Locations and Film Locations....................... 24
Engine Identification........................................... 24
Information Plate................................................ 24
Serial Number Plate........................................... 24
88
Product Description ............................................... 21
Cooling System.................................................. 22
Engine Service Life ............................................ 22
Fuel System ....................................................... 21
Ignition System .................................................. 21
Lubrication System ............................................ 22
Product Identification Information .......................... 24
Product Information Section .................................. 18
Product Lifting........................................................ 26
Engine Lifting with a Generator.......................... 26
Product Storage..................................................... 27
Generator Storage ............................................. 27
Radiator - Clean .................................................... 88
SEBU6883-08 105
Index Section

Reference Information ........................................... 25 Water Pump - Inspect ............................................ 95

Reference Information Section .............................. 96 Water Temperature Regulator - Replace............... 95
Reference Material .............................................. 100
Additional Reference Material.......................... 101
Coolants........................................................... 101
Fuels ................................................................ 101
Lubricants ........................................................ 100
Miscellaneous .................................................. 101
Reference Materials .............................................. 98
Refill Capacities..................................................... 50
Refill Capacities and Recommendations............... 50
Cooling System.................................................. 51
Fuel .................................................................... 50
Lubrication System ............................................ 50

Safety Messages ..................................................... 6

Type 1 .................................................................. 7
Type 2 .................................................................. 8
Safety Section ......................................................... 6
Sensors and Electrical Components ..................... 33
Specifications ........................................................ 22
Speed Sensor - Clean/Inspect............................... 89
Standby Generator Set Maintenance
Recommendations............................................... 89
Maintenance and Operation Procedures ........... 89
Starting Motor - Inspect ......................................... 90
Air Starting Motor ............................................... 90
Electric Starting Motor........................................ 90
Removal and Installation of the Starting Motor .. 90
Starting the Engine ................................................ 44
Automatic Starting.............................................. 45
Manual Starting.................................................. 45
Operation of the Generator Set Control Panel... 45
Purging Unburned Gas ...................................... 44
Starting with Jump Start Cables ............................ 46

Table of Contents..................................................... 3
Turbocharger - Inspect .......................................... 91

Valve Data Sheet................................................. 100

Valve Stem Projection - Measure/Record.............. 92

Walk-Around Inspection ........................................ 93

Inspect the Engine for Leaks and for Loose
Connections ..................................................... 93
Walk-Around Inspection (Exercise Inspection of
Standby Generator Set Engines)......................... 94
Warranty Information ........................................... 102
Engine Protection Plans................................... 102
106 SEBU6883-08
Index Section
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
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